Thermal-Mechanical Coupling Performance of Heat-Resistant, High-Strength and Printable Al-Si Alloy Antisymmetric...

The unsatisfactory mechanical performance at high temperatures limits the broad application of 3D-printed aluminum alloy structures in extreme environments. This study investigates the mechanical behavior of 4 different lattice cell structures in high-temperature environments using AlSi12Fe2.5Ni3Mn4, a newly developed, heat-resistant, high-strength, and printable alloy. A novel Antisymmetric anti-Buckling Lattice Cell (ASLC-B) based on a unique rotation reflection multistage design is developed. Micro-CT (Computed Tomography) and SEM (Scanning Electron Microscope) analyses revealed a smooth surface and dense interior with an average porosity of less than 0.454%. Quasi-static compression tests at 25, 100, and 200 °C showed that ASLC-B outperformed the other 3 lattice types in load-bearing capacity, energy absorption, and heat transfer efficiency. Specifically, the ASLC-B demonstrated a 51.56% and 44.14% increase in compression load-bearing capacity at 100 and 200 °C compared to ASLC-B(AlSi10Mg), highlighting its excellent high-temperature mechanical properties. A numerical model based on the Johnson-Cook constitutive relationship revealed the damage failure mechanisms, showing ASLC-B's effectiveness in preventing buckling, enhancing load-transfer efficiency, and reducing stress concentrations. This study emphasizes the importance of improving energy absorption and mechanical performance for structural optimization in extreme conditions. The ASLC-B design offers significant advancements in maintaining structural integrity and performance under high temperatures.