Topological optimisation and laser additive manufacturing of force-direction-sensitive NiTi porous structures with large deformation recovery behaviour

Abstract

ABSTRACT Optimising the cell type and configuration is a key approach for overcoming stress concentration and irreversible deformation in lightweight lattice structures with high strength. In this work, the topology optimisation method was utilised to design force-direction-sensitive structures, including face-centre loaded (FCL), central-edge loaded (CEL), and hybrid-loaded (HL) structures, which were manufactured by laser powder bed fusion (LPBF) using Nitinol (NiTi) shape memory alloy. Results indicated that the HL lattice exhibited the highest initial peak force of 7.6 kN with higher specific compressive strength (41.74 MPa·cm3/g) and specific energy absorption (6.82 J/g), which was benefit from the layer-by-layer deformation mechanism. Furthermore, the HL lattice also exhibited the best damping properties and energy absorption capacity, while achieving a high shape recovery ratio of 85%. This work offers insights into a design strategy for functional structures with high strength and large deformation recovery capacity.