The work aims to clarify the mechanical properties, deformation behavior, and energy absorption characteristics of FCC/BCC functionally gradient inlaid lattice structures under varying gradient directions and density distributions, and to identify the optimal configuration featuring low initial peak force, high crushing force efficiency, and high specific energy absorption, thereby providing design strategies and quantitative benchmarks for lightweight energy-absorbing components in high-end manufacturing. Six types of gradient inlaid lattice structures, with different gradient directions and density distributions (based on inlaid combinations of FCC and BCC unit cells), were constructed through parametric design. Quasi-static compression tests were then conducted to systematically characterize their mechanical responses, failure processes, and key energy absorption indicators, namely, initial peak force (IPF), crushing force efficiency (CFE), and specific energy absorption (SEA). All gradient structures exhibited a consistent failure mechanism: fracture initiated from the sparsest and weakest region and subsequently propagated steadily toward the denser region. Experimental results revealed that, among the six gradient configurations, the “BCC-inlaid-FCC structure” with “a high-density-low-density-high-density distribution” achieved the best overall performance, delivering the lowest IPF of 13.1 MN and the highest CFE of 2.33. The “FCC-inlaid-BCC structure” with “a reverse linear gradient” (density increasing along the loading direction) exhibited the highest SEA of 0.52 kJ/g, approximately 240% higher than that of the worst-performing configuration. The gradient pattern with “a high-density-low-density-high-density distribution” proved to be the most favorable for overall energy absorption performance, among which the FCC-inlaid-BCC combination achieved the best balance between impact mitigation and efficient energy absorption. It is concluded that, by rationally matching the matrix phase, inlaid phase, and density distribution, functionally gradient inlaid lattice structures can effectively guide progressive plastic deformation starting from weak zones, reduce the initial impact peak, and enhance crushing stability. This work provides theoretical foundations and data support for the customized design of lightweight energy absorption components in high-end manufacturing fields, such as automotive crash boxes and aviation buffer structures.
Key words
gradient lattice structure /
AlSi10Mg /
selective laser melting /
energy absorption /
failure mechanism
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Funding
The National Natural Science Foundation of China (52465045)
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