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Torsional fatigue behavior and instability-based life prediction of additively manufactured TPMS metamaterials
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DOI：10.1016/j.ijfatigue.2026.109889.png)
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Abstract
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Triply Periodic Minimal Surface (TPMS) structures are lattices based on periodic mathematical equations that are typically fabricated through the layer-by-layer process of additive manufacturing. TPMS structures have many benefits over traditional strut-based structures, such as high surface-area-to-volume ratio and reduced stress concentrations. These characteristics have caused TPMS structures to gain attention for applications such as orthopedic implants and lightweighting in biomedical and aerospace industries. For these stress-critical applications, a robust understanding of the fatigue behavior of TPMS lattices under diverse loading conditions is necessary. Although there is some information on the uniaxial fatigue behavior of lattices, components often experience local and/or remote multiaxial stresses in service. Building upon previous work on uniaxial loading, this study moves toward multiaxial loading by exploring the fatigue behavior of lattice structures subjected to pure cyclic torsional loading. Since there is no standard for the design of lattice specimens under torsional loading, two specimen geometries were designed and compared. The specimens included Ti-6Al-4V TPMS diamond and gyroid unit cells with 50% and 70% porosity. Finite element simulations with an applied shear load were completed to investigate the effects of different geometries and local stresses. X-ray computed tomography was utilized to compare CAD and printed geometries for geometric accuracy. Additionally, the previously proposed instability model was used for fatigue life prediction. Results showed tensile failure modes through ±45 ° surface cracks under shear loading and a strong correlation between porous and solid data with the same failure mechanism when applying the instability model.
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