Damage Modes and Response Mechanisms of AlSi10Mg Porous Structures Under Different Loading Strain Rates
CAI Xuanming1(), ZHANG Wei2, FAN Zhiqiang1, GAO Yubo1, WANG Junyuan3(), ZHANG Zhujun4
1 School of Aerospace Engineering, North University of China, Taiyuan 030051, China 2 School of Astronautics, Harbin Institute of Technology, Harbin 150080, China 3 School of Mechanical Engineering, North University of China, Taiyuan 030051, China 4 65589 Unit 91 Detachment, Daqing 163411, China
Cite this article:
CAI Xuanming, ZHANG Wei, FAN Zhiqiang, GAO Yubo, WANG Junyuan, ZHANG Zhujun. Damage Modes and Response Mechanisms of AlSi10Mg Porous Structures Under Different Loading Strain Rates. Acta Metall Sin, 2024, 60(7): 857-868.
AlSi10Mg is a frequently utilized aluminum alloy known for its low density, high specific strength, strong energy absorption capability, and good impact resistance. It holds significant appeal in the aviation, automotive, and machinery sectors and is particularly used as protective structures for critical aerospace components. In particular, in complex application scenarios, these protective structures are often subjected to impacts from foreign objects at different loading rates. This leads to diverse forms of damage and unpredictable damage patterns, ultimately jeopardizing key components and disrupting the normal operation of associated parts. Herein, through extensive research into the preparation, properties, and factors influencing AlSi10Mg porous structures, an understanding of the intrinsic relationship between the porous metal structure and its properties is revealed. This is important for improving material properties, expanding application possibilities, and promoting scientific and technological advancement. Exploring the application potential of AlSi10Mg porous structures across various fields offers theoretical support and technical guidance for its practical utilization. Moreover, this will provide new insights and methodologies for the future development of aluminum alloys with porous structures. By conducting a series of experimental studies, theoretical analyses, and numerical simulations, the load-bearing capacity, damage modes, and damage mechanisms of the optimized AlSi10Mg porous structures under different loading strain rates were examined. The rusults showed that the predominant damage modes in AlSi10Mg porous structures are fracture and shear damages, and the mechanical behavior is unaffected by the loading strain rates. The combination of structural damage analysis and high-precision numerical simulations revealed that under axial compressive loading, the AlSi10Mg porous structures experiences shear damage caused by relative misalignment along the diagonal cross section. This failure mode is the direct cause of the fracture damage of the structure. Furthermore, combined experimental and theoretical analyses indicated that the energy absorption properties of the AlSi10Mg porous structures are maintained at low and medium strain rates when the strain of the structures is less than 10%. When the strain exceeds 10%, the energy absorption properties at medium strain rates slightly improve compared to those at low strain rates. The energy absorption properties of the AlSi10Mg porous structures remain almost unchanged under different strain rates ranging from 378 to 1639 s-1.
Fig.1 Schematics of main forming modes for optimization and design of AlSi10Mg porous structure (δ—wall thickness)
Fig.2 Schematic of medium strain rate loading experimental device (v0—speed in the loading direction)
Fig.3 Schematic of improved split Hopkinson pressure bar (SHPB) experimental device
Parameter
Symbol
Value
Unit
Yield strength parameter
M
331.17
MPa
Model parameter
B
576.65
MPa
Strain rate sensitive parameter
C
0.032
Hardening index
n
0.99
Temperature softening parameter
m
0.945
Reference strain rate
1
s-1
Reference temperature
Tr
298
K
Melting point temperature
Tm
843
K
Material model parameter
D1
0.04704
D2
1.155
D3
-0.841
D4
-0.042
D5
0
Material density
ρ
2700
kg·m-3
Elastic modulus
E
75
GPa
Poisson's ratio
ν
0.3
Table 1 Correlation parameters of the Johnson-Cook principal model and fracture criterion
Fig.4 SEM image (a) and particle size distribution (b) of the AlSi10Mg alloy powders
Fig.5 Stress-strain curves of AlSi10Mg porous struc-ture under different strain rates (a) low and medium strain rates (b) high strain rates
Fig.6 Deformation failure mode (a-d, f-i, k-n) and schematics of damage location (dash lines) (e, j, o) at the first region (a-e), the second region (f-j), and the third region (k-o) of AlSi10Mg porous structure at low strain rates (0.009 s-1) (elastic deformation, the strain ε ≈ 2%; first fracture, ε ≈ 6.7%; collapse, ε ≈ 30%)
Fig.7 Deformation failure mode (a-c) and schematic of damage location (dash line) (d) of AlSi10Mg porous structure under medium strain rate loading (50 s-1) (a) initial status (b) first fracture (ε ≈ 8.7%) (c) serious damage (ε ≈ 25%)
Fig.8 Deformation and failure modes of AlSi10Mg porous structure under high strain rate loading of 1137 s-1 captured by high-speed camera for 0 μs (a), 50 μs (b), 100 μs (c), 150 μs (d), and 200 μs (e) (v—impact velocity of the striker)
Fig.9 Numerical simulation results of the load-bearing state of the AlSi10Mg porous structure at low strain rate (0.009 s-1) as the strain is 2% (a) the first region (b) the second region (c) the third region
Fig.10 Numerical simulation results of failure modes of AlSi10Mg porous structure under low strain rate (0.009 s-1) as the strain is 7.7% (a) the first region (b) the second region (c) the third region
Fig.11 Numerical simulation results of bearing state and deformation failure mode of AlSi10Mg porous structure under medium strain rate (50 s-1) at strains of 1% (a-c), 8.7% (d-f), and 25% (g-i) (a, d, g) the first regions (b, e, h) the second regions (c, f, i) the third regions
Fig.12 Numerical simulation results of deformation and failure modes of AlSi10Mg porous structure under high strain rate (1137 s-1) when the loading time is 150 μs (a-c), 165 μs (d-f), and 200 μs (g-i) (a, d, g) the first regions (b, e, h) the second regions (c, f, i) the third regions
Fig.13 Energy absorption characteristics of AlSi10Mg porous structure under low and medium strain rates (a), and different high strain rates (b)
Fig.14 Efficiency of energy absorptions of AlSi10Mg porous structure under low and medium strain rates (a), and different high strain rates (b)
1
Tiwari J K, Mandal A, Sathish N, et al. Investigation of porosity, microstructure and mechanical properties of additively manufactured graphene reinforced AlSi10Mg composite [J]. Addit. Manuf., 2020, 33: 101095
2
Li Z H, Nie Y F, Liu B, et al. Mechanical properties of AlSi10Mg lattice structures fabricated by selective laser melting [J]. Mater. Des., 2020, 192: 108709
3
Yang T, Liu T T, Liao W H, et al. Laser powder bed fusion of AlSi10Mg: Influence of energy intensities on spatter and porosity evolution, microstructure and mechanical properties [J]. J. Alloys Compd., 2020, 849: 156300
4
Schuch M, Hahn T, Bleckmann M. The mechanical behavior and microstructure of additively manufactured AlSi10Mg for different material states and loading conditions [J]. Mater. Sci. Eng., 2021, A813: 141134
5
Zhang Y F, Majeed A, Muzamil M, et al. Investigation for macro mechanical behavior explicitly for thin-walled parts of AlSi10Mg alloy using selective laser melting technique [J]. J. Manuf. Process., 2021, 66: 269
6
Li X F, Yi D H, Wu X Y, et al. Effect of construction angles on microstructure and mechanical properties of AlSi10Mg alloy fabricated by selective laser melting [J]. J. Alloys Compd., 2021, 881: 160459
7
AlQaydi H A, Krishnan K, Oyebanji J, et al. Hybridisation of AlSi10Mg lattice structures for engineered mechanical performance [J]. Addit. Manuf., 2022, 57: 102935
8
Butler C, Babu S, Lundy R, et al. Effects of processing parameters and heat treatment on thermal conductivity of additively manufactured AlSi10Mg by selective laser melting [J]. Mater. Charact., 2021, 173: 110945
9
Sun Q D, Sun J, Guo K, et al. Investigation on mechanical properties and energy absorption capabilities of AlSi10Mg triply periodic minimal surface sheet structures fabricated via selective laser melting [J]. J. Mater. Eng. Perform., 2022, 31: 9110
10
Johnson Q C, Laursen C M, Spear A D, et al. Analysis of the interdependent relationship between porosity, deformation, and crack growth during compression loading of LPBF AlSi10Mg [J]. Mater. Sci. Eng., 2022, A852: 143640
11
Chen Y, Ren Y M, Li K, et al. Laser powder bed fusion of oxidized microscale SiC-particle-reinforced AlSi10Mg matrix composites: Microstructure, porosity, and mechanical properties [J]. Mater. Sci. Eng., 2023, A870: 144860
12
Maleki E, Bagherifard S, Unal O, et al. Effects of different mechanical and chemical surface post-treatments on mechanical and surface properties of as-built laser powder bed fusion AlSi10Mg [J]. Surf. Coat. Technol., 2022, 439: 128391
13
Hirata T, Kimura T, Nakamoto T. Effect of internal pores on fatigue properties in selective laser melted AlSi10Mg alloy [J]. Mater. Trans., 2022, 63: 1013
14
Kolev M, Drenchev L, Simeonova T, et al. Data on mechanical pro-perties of open-cell AlSi10Mg materials and open-cell AlSi10Mg-SiC composites with different pore sizes and strain rates [J]. Data Brief, 2023, 49: 109461
15
Pezzato L, Dabalà M, Gross S, et al. Effect of microstructure and porosity of AlSi10Mg alloy produced by selective laser melting on the corrosion properties of plasma electrolytic oxidation coatings [J]. Surf. Coat. Technol., 2020, 404: 126477
16
Yue D Y, Li D M, Zhang X, et al. Tensile behavior of AlSi10Mg overhanging structures fabricated by laser powder bed fusion: Effects of support structures and build orientation [J]. Mater. Sci. Eng., 2023, A880: 145375
17
Dynin N V, Antipov V V, Khasikov D V, et al. Structure and mechani-cal properties of an advanced aluminium alloy AlSi10MgCu(Ce, Zr) produced by selective laser melting [J]. Mater. Lett., 2021, 284: 128898
18
Nezhadfar P D, Thompson S, Saharan A, et al. Structural integrity of additively manufactured aluminum alloys: Effects of build orientation on microstructure, porosity, and fatigue behavior [J]. Addit. Manuf., 2021, 47: 102292
19
Wang P S, Salandari-Rabori A, Dong Q S, et al. Effect of input powder attributes on optimized processing and as-built tensile properties in laser powder bed fusion of AlSi10Mg alloy [J]. J. Manuf. Process., 2021, 64: 633
20
Schukraft J, Roßdeutscher J, Siegmund F, et al. Thermal expansion behavior and elevated temperature elastic properties of an interpenetrating metal/ceramic composite [J]. Thermochim. Acta, 2022, 715: 179298
21
Yaokawa J, Oh-Ishi K, Dong S X, et al. Dimensional changes of selectively laser-melted AlSi10Mg alloy induced by heat treatment [J]. Mater. Trans., 2023, 64: 697
22
Yusuf S M, Mazlan N, Musa N H, et al. Microstructures and hardening mechanisms of a 316L stainless steel/Inconel 718 interface additively manufactured by multi-material selective laser melting [J]. Metals, 2023, 13: 400
23
Du D F, Wang L, Dong A P, et al. Promoting the densification and grain refinement with assistance of static magnetic field in laser powder bed fusion [J]. Int. J. Mach. Tools Manuf., 2022, 183: 103965
24
Tang H, Geng Y X, Luo J J, et al. Mechanical properties of high Mg-content Al-Mg-Sc-Zr alloy fabricated by selective laser melting [J]. Met. Mater. Int., 2021, 27: 2592
25
Parsons E M, Shaik S Z. Additive manufacturing of aluminum metal matrix composites: Mechanical alloying of composite powders and single track consolidation with laser powder bed fusion [J]. Addit. Manuf., 2022, 50: 102450
26
Fathi-Hafshejani P, Soltani-Tehrani A, Shamsaei N, et al. Laser incidence angle influence on energy density variations, surface roughness, and porosity of additively manufactured parts [J]. Addit. Manuf., 2022, 50: 102572
27
Muhammad W, Brahme A P, Ibragimova O, et al. A machine learning framework to predict local strain distribution and the evolution of plastic anisotropy & fracture in additively manufactured alloys [J]. Int. J. Plast., 2021, 136: 102867
28
Miao K, Zhou H, Gao Y P, et al. Laser powder-bed-fusion of Si3N4 reinforced AlSi10Mg composites: Processing, mechanical properties and strengthening mechanisms [J]. Mater. Sci. Eng., 2021, A825: 141874
29
Xing X D, Duan X M, Sun X J, et al. Modification of residual stresses in laser additive manufactured AlSi10Mg specimens using an ultrasonic peening technique [J]. Materials, 2019, 12: 455
30
Nurel B, Nahmany M, Frage N, et al. Split Hopkinson pressure bar tests for investigating dynamic properties of additively manufactured AlSi10Mg alloy by selective laser melting [J]. Adv. Manuf., 2018, 22: 823
31
Zaretsky E, Stern A, Frage N. Dynamic response of AlSi10Mg alloy fabricated by selective laser melting [J]. Mater. Sci. Eng., 2017, A688: 364
32
Baxter C, Cyr E, Odeshi A, et al. Constitutive models for the dynamic behaviour of direct metal laser sintered AlSi10Mg_200C under high strain rate shock loading [J]. Mater. Sci. Eng., 2018, A731: 296
33
Hadadzadeh A, Amirkhiz B S, Odeshi A, et al. Dynamic loading of direct metal laser sintered AlSi10Mg alloy: Strengthening behavior in different building directions [J]. Mater. Des., 2018, 159: 201
34
Zhang Y W, Liu T, Ren H, et al. Dynamic compressive response of additively manufactured AlSi10Mg alloy hierarchical honeycomb structures [J]. Compos. Struct., 2018, 195: 45
35
Aktürk M, Boy M, Gupta M K, et al. Numerical and experimental investigations of built orientation dependent Johnson-Cook model for selective laser melting manufactured AlSi10Mg [J]. J. Mater. Res. Technol., 2021, 15: 6244
36
Feng Z, Wang X M, Tan H, et al. Effect of heat treatment patterns on porosity, microstructure, and mechanical properties of selective laser melted TiB2/Al-Si-Mg composite [J]. Mater. Sci. Eng., 2022, A855: 143932
37
Zhang Y W, Lin Y L, Li Y, et al. 3D printed self-similar AlSi10Mg alloy hierarchical honeycomb architectures under in-plane large deformation [J]. Thin-Wall. Struct., 2021, 164: 107795
38
Amir B, Kochavi E, Gruntman S, et al. Experimental investigation on shear strength of laser powder bed fusion AlSi10Mg under quasi-static and dynamic loads [J]. Addit. Manuf., 2021, 46: 102150
39
Roth C C, Tancogne-Dejean T, Mohr D. Plasticity and fracture of cast and SLM AlSi10Mg: High-throughput testing and modeling [J]. Addit. Manuf., 2021, 43: 101998
40
Sharma S K, Grewal H S, Saxena K K, et al. Advancements in the additive manufacturing of magnesium and aluminum alloys through laser-based approach [J]. Materials, 2022, 15: 8122
41
Matus K, Matula G, Pawlyta M, et al. TEM study of the microstructure of an alumina/Al composite prepared by gas-pressure infiltration [J]. Materials, 2022, 15: 6112
42
Li Y N, Zhan J, Song C H, et al. Design and performance of a novel neutron shielding composite materials based on AlSi10Mg porous structure fabricated by laser powder bed fusion [J]. J. Alloys Compd., 2023, 968: 172180
43
Maskery I, Aboulkhair N T, Aremu A O, et al. Compressive failure modes and energy absorption in additively manufactured double gyroid lattices [J]. Addit. Manuf., 2017, 16: 24
44
Di Egidio G, Ceschini L, Morri A, et al. A novel T6 rapid heat treatment for AlSi10Mg alloy produced by laser-based powder bed fusion: Comparison with T5 and conventional T6 heat treatments [J]. Metall. Mater. Trans., 2022, 53B: 284
45
Li D M, Zhang X, Qin R X, et al. Influence of processing parameters on AlSi10Mg lattice structure during selective laser melting: Manufacturing defects, thermal behavior and compression properties [J]. Opt. Laser Technol., 2023, 161: 109182
46
Gao C, Wang Z, Xiao Z, et al. Selective laser melting of TiN nanoparticle-reinforced AlSi10Mg composite: Microstructural, interfacial, and mechanical properties [J]. J. Mater. Process. Technol., 2020, 281: 116618
47
Smith B A, Laursen C M, Bartanus J, et al. The interplay of geometric defects and porosity on the mechanical behavior of additively manufactured components [J]. Exp. Mech., 2021, 61: 685
48
Xiao H F, Zhang C C, Zhu H H. Effect of direct aging and annealing on the microstructure and mechanical properties of AlSi10Mg fabricated by selective laser melting [J]. Rapid Prototyping J., 2023, 29: 118
49
Wang X, Qin R X, Chen B Z. Laser-based additively manufactured bio-inspired crashworthy structure: Energy absorption and collapse behaviour under static and dynamic loadings [J]. Mater. Des., 2021, 211: 110128
50
Qiu J Q, Chen C J, Zhang M. Effects of graphene on the mechanical properties of AlSi10Mg melted by SLM [J]. Mater. Sci. Technol., 2022, 38: 804
