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<p>This study investigates the fatigue performance of gyroid and diamond lattice structures fabricated by laser powder bed fusion (L-PBF) at porosity levels of 60%, 70%, And 80%. The lattice structures were fabricated from Ti6Al4V alloy And subjected to comprehensive fatigue testing to evaluate their behavior under cyclic loading. High-cycle fatigue tests were performed under compression-compression loading conditions, And the fatigue lives of the samples were determined based on a 90% stiffness degradation criterion. Fatigue strength significantly declined with increasing porosity in both gyroid and diamond lattices. Gyroid lattices outperformed diamond lattices at the same porosity levels, likely due to their surface-based geometry that enables more uniform stress distribution. In contrast, diamond lattices experienced localized stress concentrations, leading to premature failure. The fracture surfaces of the fatigued samples were analyzed via scanning electron microscopy (SEM) to investigate crack initiation and propagation mechanisms, revealing that surface defects and unmelted powder particles played a critical role in the fatigue failure of both lattice types. This research provides valuable insights into the fatigue behavior of gyroid and diamond lattice structures, particularly for lightweight applications requiring long-term durability, such as in biomedical implants and aerospace components. These findings highlight the critical role of lattice design and porosity in optimizing fatigue performance.</p>

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Fatigue performance of additively manufactured gyroid and diamond lattice structures with varying porosities

  • 期刊论文

  • 发表日期：

    2025年9月9日

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  • Gürkan Kaya,
  • Fatih Yıldız,
  • İsmail Hakkı Korkmaz,
  • Ali Fatih Yetim,
  • İrfan Kaymaz

摘要

This study investigates the fatigue performance of gyroid and diamond lattice structures fabricated by laser powder bed fusion (L-PBF) at porosity levels of 60%, 70%, And 80%. The lattice structures were fabricated from Ti6Al4V alloy And subjected to comprehensive fatigue testing to evaluate their behavior under cyclic loading. High-cycle fatigue tests were performed under compression-compression loading conditions, And the fatigue lives of the samples were determined based on a 90% stiffness degradation criterion. Fatigue strength significantly declined with increasing porosity in both gyroid and diamond lattices. Gyroid lattices outperformed diamond lattices at the same porosity levels, likely due to their surface-based geometry that enables more uniform stress distribution. In contrast, diamond lattices experienced localized stress concentrations, leading to premature failure. The fracture surfaces of the fatigued samples were analyzed via scanning electron microscopy (SEM) to investigate crack initiation and propagation mechanisms, revealing that surface defects and unmelted powder particles played a critical role in the fatigue failure of both lattice types. This research provides valuable insights into the fatigue behavior of gyroid and diamond lattice structures, particularly for lightweight applications requiring long-term durability, such as in biomedical implants and aerospace components. These findings highlight the critical role of lattice design and porosity in optimizing fatigue performance.