Improved energy absorption and mechanical properties of porous Ti-6Al-4V alloys with gradients disordered cell fabricated via laser powder bed fusion

In this study, we explore the properties of porous Ti-6Al-4V alloys produced via through laser powder bed fusion (L-PBF), which are advanced materials offering tailored mechanical properties and enhanced energy absorption capabilities. The incorporation of gradient disordered cells into the cellular structure improves both the structural integrity and energy absorption of these alloys, making them sell-suited for applications in aerospace, biomedical, and automotive applications, where components need to be lightweight yet durable. We systematically adjust the degree of disorder in the samples, focusing on their compressive strength, energy absorption, and failure mechanisms. To evaluate these properties, a hybrid approach combining quasi-static compression tests and finite element analysis (FEA) is utilized. The results indicate that incorporating a disordered gradient within a structured matrix significantly enhances energy absorption capabilities, evidenced by a rise of up to 197.9 %. Additionally, this configuration effectively mitigates the development of shear bands, which typically manifest in ordered cellular structures. An optimal configuration emerges when employing a ruling factor of 0.8, characterized by dual layers of disordered cells. This configuration surpasses both purely ordered and entirely disordered structures, highlighting its significant potential for enhancing mechanical properties in lightweight design. These advancements broaden the applicability of the material in sectors such as aerospace, biomedicine, and protective equipment. Despite these significant improvements, challenges related to regularity variance remain, offering avenues for future research into the influence of cellular geometry and regularity on material properties. •Disordered cell gradients enhance energy absorption by up to 197.9 %.•Optimal configuration found with 0.8 regularity and two disordered layers.•Increased structural stability and mechanical performance.•Comprehensive FEA correlates with experimental compression tests.•Novel design strategy using disordered gradients improves material performance.