Microstructure-dependent deformation mechanisms and fracture modes of gradient porous NiTi alloys

Gradient porous structures based on triply periodic minimal surfaces offer exceptional specific strength and multi-functionality. However, strain heterogeneity complicates their deformation mechanisms and fracture modes. In this study, we fabricated a series of gradient porous NiTi alloys based on gyroid (G), diamond (D), and I-WP (I) unit cells, with porosities ranging from 50% to 70%. Surprisingly, the I structure exhibited an abnormally high compressive strength of nearly 600 MPa at around 50% porosity, more than twice that of the G and D structures. This performance gap was attributed to the activation of mixed deformation mechanisms and distinct fracture modes. While the G structure showed a uniform radial strain distribution, the D and I structures displayed pronounced radial strain gradients with concentrated central strains. The D structure deformed through relative sliding of oblique struts, while the I structure maintained macrostructural stability, with thick edge struts providing continuous strain hardening until monolithic fracture. This unique deformation behavior results from the synergistic effects of its intrinsic macrostructural stability, significant radial strain gradients, and sufficiently thicker edge struts. The integration of metallurgical and architectural design principles represents a novel approach to tailoring the mechanical properties of gradient porous metals for advanced applications.