Dimensional effect and mechanical performance of node-strengthened hybrid lattice structure fabricated by laser powder bed fusion

Node-strengthened hybrid structures with lower relative density inspired by solid solution strengthening mechanism, namely the edge center interstitial lattice (ECIL) structures and vertex node substitutional lattice (VNSL) structures were designed and fabricated by laser powder bed fusion (LPBF). The geometric feature-dependent defects distribution, the intense microstructure sensitivity as well as the node size effect on the mechanical response were investigated. The microstructure sensitivity induced by geometric feature was found to be related to the different supporting condition and distinctive thermal history. ECIL-1.5 structure possessed the highest plateau stress of 1.79 MPa and the largest crush force efficiency of 59.1%, which increased by 59.8% and 15.2% compared to the initial face centre cubic with z-struts (FCCZ)structure. VNSL-1.5 exhibited the greatest specific energy absorption of 14.6 J/g, demonstrating the highest strengthening efficiency was achieved at the critical sphere diameter to strut thickness (Sph-strut) ratio of 3. This method further improved lightweight efficiency, indicating the inherent strengthening mechanism of crystal materials could guide the design of metamaterials.