Abstract
As the utilization of additively manufactured (AM) functionally graded porosity (FGP) structures continues to rise in various industries, there is a growing need for a comprehensive understanding of their design, microstructure, mechanical behavior, and failure mechanisms. This study involves the design and fabrication of FGP specimens with an 85 % volume fraction using selective laser melting (SLM) and 316L stainless steel powder, focusing on characterizing porosities, printing quality, and microstructure. Experimental tests, including tensile, quasi-static compression, and Split Hopkinson Pressure Bar tests, are conducted to assess the material behavior. Additionally, finite element analysis (FEA) and experimental compression tests are employed to investigate the compressive mechanical behavior and failure modes of FGP structures. The findings indicate that porosity distribution has minimal impact on the compressive behavior, specific energy absorption (SEA), and toughness of FGP structures. Furthermore, reducing the volume fraction from 85 % to 75 % in the S1FG samples increases the SEA by 7.2 % and changes the toughness by 5.9 %. Notably, porosity distribution influences fracture position and failure mechanisms during compression tests.
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