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<p>Additive manufacturing (AM) is a key technology for fabricating complex metal lattice structures that can be utilized to produce novel interpenetrating-phase composites (IPCs). This study presents a comprehensive investigation into the fabrication and mechanical behavior of H13 tool steel/Cu IPCs with an octet-truss lattice architecture. A hybrid manufacturing process, combining laser powder bed fusion (LPBF) to build H13 lattice scaffolds and subsequent pressureless infiltration of a Cu matrix, was developed to produce near fully-dense IPCs with exceptionally low residual porosity (&lt; 0.03%). Micro-computed tomography was used to characterize the co-continuous microstructure and interface. Moreover, the compressive mechanical behavior of the H13/Cu IPCs was experimentally investigated, revealing that the compressive yield strength (CYS) increases based on a power-law relation from 474&#xa0;MPa to 1405&#xa0;MPa with increasing H13 volume fraction from 0.46 to 0.88. Furthermore, finite element modeling (FEM) simulations were conducted to understand the deformation and yielding mechanisms at the unit cell (UC) level, demonstrating excellent agreement with experimental data, with CYS deviations ranging from 3% to 13%. The computational efficiency of the UC model was also validated against a full-scale model, confirming its accurate prediction of the CYS with a 12% difference. The simulations confirmed that macroscopic yielding of the IPCs initiates in the softer Cu phase, followed by localized yielding in the H13 lattice scaffold. This work provides critical insights into the multi-scale mechanical behavior of novel H13/Cu IPCs, contributing to the development of multifunctional architected materials for die and mold applications.</p>

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Tailorable compressive properties of H13/Cu interpenetrating phase composite produced by laser powder bed fusion and pressureless infiltration

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Mahmoud Osman,
  • Priti Wanjara,
  • Javad Gholipour,
  • Fabrice Bernier,
  • Marjan Molavi-Zarandi,
  • Muralidharan Kumar,
  • Mathieu Brochu

摘要

Additive manufacturing (AM) is a key technology for fabricating complex metal lattice structures that can be utilized to produce novel interpenetrating-phase composites (IPCs). This study presents a comprehensive investigation into the fabrication and mechanical behavior of H13 tool steel/Cu IPCs with an octet-truss lattice architecture. A hybrid manufacturing process, combining laser powder bed fusion (LPBF) to build H13 lattice scaffolds and subsequent pressureless infiltration of a Cu matrix, was developed to produce near fully-dense IPCs with exceptionally low residual porosity (< 0.03%). Micro-computed tomography was used to characterize the co-continuous microstructure and interface. Moreover, the compressive mechanical behavior of the H13/Cu IPCs was experimentally investigated, revealing that the compressive yield strength (CYS) increases based on a power-law relation from 474 MPa to 1405 MPa with increasing H13 volume fraction from 0.46 to 0.88. Furthermore, finite element modeling (FEM) simulations were conducted to understand the deformation and yielding mechanisms at the unit cell (UC) level, demonstrating excellent agreement with experimental data, with CYS deviations ranging from 3% to 13%. The computational efficiency of the UC model was also validated against a full-scale model, confirming its accurate prediction of the CYS with a 12% difference. The simulations confirmed that macroscopic yielding of the IPCs initiates in the softer Cu phase, followed by localized yielding in the H13 lattice scaffold. This work provides critical insights into the multi-scale mechanical behavior of novel H13/Cu IPCs, contributing to the development of multifunctional architected materials for die and mold applications.