Production of aluminum alloy cellular structures and mechanical characterization through compression and hardness tests

AbstractIn this study, the mechanical behavior of aluminum alloy AA6082 cellular structures produced via the lost-PLA replication method was analyzed. This cost-effective and straightforward manufacturing technique involves the manufacturing of a PLA model using 3D printing, which is subsequently transformed into a metallic structure through casting techniques.The produced structures exhibited a well-defined morphology, high surface quality and a strong correlation between experimental weight and theoretical values, confirming the reliability of the replication process. Compression tests, performed on portions of the structures due to technical limitations, revealed a mechanical response characterized by an initial linear elastic phase, a plateau and a final densification phase, during which an abrupt load increase was observed.Specific energy absorption (SEA), computed from the nominal stress–strain curve and referred to the external specimen volume, reached about 26 J/cm3 for the tested cut-out specimens (average external volume ≈ 1.29 cm3, mass ≈ 1.4 g).These results demonstrate the reproducibility of the manufacturing process and the reliable mechanical response of Lost-PLA aluminum cellular structures intended for lightweight energy-absorbing components, with potential relevance for structural protection in hydrogen-powered mobility systems.