Mechanical Properties and Energy Absorption of Integrated AlSi10Mg Shell Structures with BCC Lattice Infill

Shell-infill structures comprise an exterior solid shell and an interior lattice infill, whose closed features yield superior comprehensive mechanical performance and light weight. Additive manufacturing (AM) can ensure the fabrication of complex structures. Although the mechanical behaviors of lattice structures have been extensively studied, the corresponding mechanical performances of integrated-manufactured shell structures with lattice infills should be systematically investigated due to the coupling effect of the exterior shell and lattice infill. This study investigated the mechanical properties and energy absorption of AlSi10Mg shell structures with a body-centered cubic lattice infill fabricated by AM. Quasi-static compressive experiments and corresponding finite element analysis were conducted to investigate the mechanical behavior. In addition, two different finite element modeling methods were compared to determine the appropriate modeling strategy in terms of deformation behavior. A study of different parameters, including lattice diameters and shell thicknesses, was conducted to identify their effect on mechanical performance. The results demonstrate the mechanical advantages of shell-infill structures, in which the exterior shell strengthens the lattice infill by up to 2.3 times in terms of the effective Young’s modulus. Increasing the infill strut diameter can improve the specific energy absorption by up to 1.6 times.