Laser additive manufacturing of ODS CuCrZr TPMS lattice structures with enhanced mechanical-thermal performance

To address the urgent demand for efficient thermal management components in aerospace and related fields, this study proposes an optimization method integrating material composition and macrostructural design. Utilizing this approach, a triply periodic minimal surface (TPMS) lattice structure composed of oxide dispersion-strengthened CuCrZr alloy was fabricated via laser powder bed fusion (LPBF) technology. In the material composition design, the influence of Y2O3 doping (ranging from 0 to 2.0 wt%) on the mechanical and thermal properties of CuCrZr composites was systematically investigated. The results indicate that 0.5 wt% Y2O3 exhibits the best overall performance, with its room temperature ultimate tensile strength and thermal conductivity improved by 16.2 % and 8.11 %, respectively, compared to the undoped alloy. The enhanced mechanical properties primarily result from the synergy of Y2O3-induced precipitation strengthening and grain refinement, while the improved thermal conductivity stems from reduced metallurgical defects and optimized heat conduction pathways. At the structural design level, four TPMS configurations—Gyroid, Diamond, Primitive, and I-WP—were evaluated through a combination of experiments and simulations. In these structures, the diamond lattice structure exhibits excellent thermal (achieving Nusselt number of 740.75 at Reynolds number of 1445.5) and mechanical properties (with elastic modulus of 1127.53 MPa and peak plateau stress of 18.67 MPa). Its high specific surface area and tortuous flow channels enhance airflow disturbance, while its shear failure mode offers advantages in load-bearing capacity and energy absorption. The proposed optimization method facilitates integrated fabrication of high-load, high-efficiency components and lightweight, high-strength TPMS lattice structures for thermal management.