Compression Behaviour of L-PBF-Manufactured Ti6Al4V BCC Lattices

Laser powder bed fusion (L-PBF) is a widely used additive manufacturing technique that enables the creation of complex lattice structures with applications in biomedical implants and aerospace components. This study investigates the impact of relative density and the geometric parameters (unit cell size and strut diameter) of body-centred cubic (BCC) lattices on the compressive mechanical properties of Ti-6Al-4V (Ti64) lattices manufactured using continuous wave L-PBF. The as-built and heat-treated samples were evaluated for their Young’s modulus, strength, and ductility. Lattices with varying unit cell sizes (1–3 mm) and strut diameters (0.3–1.2 mm) were fabricated, resulting in relative densities ranging from 10% to 77%. All of these samples exhibited a 45° shear failure, which was attributed to the alignment of the principal stress planes with the lattice struts under compression, leading to shear band formation. This study provides critical insights into the interplay between geometric parameters, microstructure evolution, and resultant mechanical properties, contributing to the experimental validation of solid vs. lattice samples fabricated under identical conditions. Fractography analysis revealed that the as-built samples exhibited predominantly brittle fracture characteristics, while heat-treated samples displayed mixed fracture modes with increased ductility. Results indicate that heat treatment enhances mechanical properties, yielding comparable compressive strength (approx. 20% decrease), a reduced modulus of elasticity (approx. 30% decrease), and increased ductility (approx. 10% increase). This is driven by microstructural changes, such as the phase transformation from α’ martensitic needles to α + β, and thus relieves the residual stress to some degree. By addressing the microstructure–property correlations and failure mechanisms, this work establishes guidelines for optimizing lattice designs for biomedical and aerospace applications, emphasizing the critical role of geometric parameters and thermal treatment in tailoring mechanical behaviour.