Experimental Study of Three AlSi10Mg Cellular Structures with Triply Periodic Minimal Surface (TPMS) Topology Subjected to Bending Loading and Identification of Root Aspects of Possible Premature Failure

The manuscript deals with the bending behavior of beams with relatively less investigated cellular topologies based on triply periodic minimal surfaces (TPMSs). Three types of sandwich-type specimens (namely Schoen IWP, Fischer–Koch S, and Schoen F-RD) with five different volume fractions of 10, 15, 20, 25, and 35% (±1%) made of aluminum alloy AlSi10Mg by selective laser melting (SLM) technology were investigated. Three-point bending tests were performed at room temperature on a Zwick/Roell 1456 universal testing machine. The force–deflection dependences were plotted, while in addition to nominal stresses, the effective flexural stiffness and energy absorption to failure were evaluated to compare the properties of the investigated cellular beams. In the preparatory phase, critical aspects of possible premature failure of the samples with the smallest and highest selected volume fractions were addressed, while the manufacturability and fracture surfaces of the samples were assessed in order to improve the input conditions of the setup. By comparing the results obtained in the experimental testing in the second phase, it was found that the highest nominal bending stresses were achieved by the Schoen F-RD structure (although not significantly higher than Fischer–Koch S), but in terms of stiffness and amount of absorbed energy, the Fischer–Koch S structure showed the highest values. The improvement of input parameters led to an increase in the achieved nominal bending stresses by at least 100 MPa for all types of investigated structures compared to the first phase. The combined use of preliminary SLM process optimization, bending tests, and fracture surface/EDX analysis made it possible to relate the flexural response of the investigated TPMS topologies to manufacturing-related defects and premature-failure mechanisms in thin-walled AlSi10Mg cellular structures. The presented specimen configuration is intended as a comparative experimental benchmark for flexural performance of sandwich-type TPMS beams under quasi-static loading.