Damage Modes and Response Mechanisms of AlSi10Mg Porous Structures Under Different Loading Strain Rates

doi:10.11900/0412.1961.2023.00440

Acta Metall Sin

2024, Vol. 60

Issue (7): 857-868 DOI: 10.11900/0412.1961.2023.00440

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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

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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.

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Abstract

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.

Key words: porous structure selective laser melting mechanical behavior energy absorption shear failure

Received: 07 November 2023

ZTFLH:

TG111.3

Fund: State Key Laboratory of Dynamic Measurement Technology(2022-SYSJJ-03)

Corresponding Authors: CAI Xuanming, associate professor, Tel: (0351)3922272, E-mail: caixm@nuc.edu.cn;

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	CAI Xuanming
	ZHANG Wei
	FAN Zhiqiang
	GAO Yubo
	WANG Junyuan
	ZHANG Zhujun

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00440 OR https://www.ams.org.cn/EN/Y2024/V60/I7/857

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	$ε ˙ 0$	1	s^-1
Reference temperature	T_r	298	K
Melting point temperature	T_m	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)

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