18Ni300/AlSi10Mg interpenetrating phase composite: Lattice structure, mechanical and thermal performance, and application in forming die

A three-dimensional interpenetrating structure is a promising design that enhances the mechanical properties and functionality of bimetallic materials, where the structure and distribution of each phase are crucial in determining the final performance of the composite material. In this study, we propose a novel radial gradient design strategy to manufacture single-phase lattice structures. The results show that this design not only improves the yield strength of the lattice structure but also increases its surface area, thereby accelerating heat dissipation. These structures are then subjected to a pressureless infiltration to form interpenetrating phase composites (IPCs). Mechanical interlocking at the interface, heterogeneous deformation-induced (HDI) strengthening, and continuous thermal conduction paths enable IPCs to exhibit excellent mechanical properties and thermal conductivity. Utilizing these insights, we designed and manufactured an advanced hot stamping die composed of lattice structures and IPCs. Tests confirm that this die has less thermal accumulation and a higher blank cooling rate. This case offers a promising solution for manufacturing cost-effective and high cooling-efficiency hot stamping dies. [Display omitted] •Lattice structures with radial dual-feature gradients were fabricated via LPBF.•18Ni300/AlSi10Mg IPCs were prepared by LPBF and pressureless infiltration.•Designed and manufactured a hot stamping die with lattice structures and IPCs.•This die offers improved cost-effectiveness and enhanced cooling efficiency.