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Materials Science in Additive Manufacturing Impact of cell angle on AlSi10Mg structures

1. Introduction research has predominantly concentrated on static
deformations under various conditions, thus creating a gap
Porous structures have recently attracted significant in experimental evidence regarding their dynamic impact
research interest due to their exceptional properties, behavior.
including high specific strength, excellent vibration and
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impact resistance, low elastic modulus, low thermal Metal additive manufacturing (AM) technology,
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conductivity, and superior specific energy absorption which allows precise control of geometric structures
(SEA). These characteristics make them highly suitable through layer-by-layer stacking, offers a promising
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for applications in aerospace, biomedical engineering, and solution for producing complex and functional solid and
other fields where effective energy absorption is crucial to porous structures. 28,29 This technology has emerged as a
minimize damage to internal components and personnel supplementary technique to conventional manufacturing
during impact events. In recent years, various energy methods for producing metallic components, 30-32 while
absorption structures have been studied, 10-13 including also achieving considerable mechanical performance for
column structures, sandwich structures, honeycomb metals. 33-35 Laser powder bed fusion (LPBF), also known as
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structures, foam structures, triply periodic minimal selective laser melting, is a pivotal aspect of laser AM and
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surface structures, and other lattice structures. 19,20 serves as a versatile method for fabricating various metallic
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While these designs exhibit enhanced energy absorption components with tuned microstructures for enhanced
capabilities, further optimization is still needed to mechanical performance. In addition, it facilitates
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maximize performance. For example, Serban et al. surface treatments for improved corrosion resistance and
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demonstrated that controlling the relative density of enables the exploration of flexible powder design. Due to
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porous structures can be achieved by adjusting key design their lightweight nature, corrosion resistance, and other
parameters such as strut thickness, strut length, and fillet favorable properties, aluminum alloys are widely used in
radius. Wu et al. incorporated solid cylinders of varying metal component manufacturing. 39-41 Among these, the
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diameters into lattice structures while maintaining similar AlSi10Mg alloy is particularly favored in LPBF technology
porosity, significantly improving compressive strength and due to its well-established melting characteristics and
impact energy absorption. Adjusting these parameters consistent mechanical properties within an optimized
makes it possible to achieve a balance that satisfies both processing window. As such, investigating the dynamic
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the demand for lightweight characteristics and the impact behavior of AlSi10Mg-based porous structures will
requirements for strength. These findings underscore the provide insights into their mechanical response and energy
potential of parameter tuning to optimize the trade-off absorption characteristics, focusing on the influence of
between lightweight design and mechanical performance. unit cell design.
Given the importance of dynamic loading in practical Recent literature has highlighted differences in
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applications, researchers are increasingly focusing on the the load-carrying capacity of various bearing surfaces
dynamic characteristics of porous structures. Numerous within a single-unit cell, providing a foundation for
studies 22-25 have investigated the dynamic mechanical investigating the mechanical properties of rotating single-
properties of porous metal materials. For instance, Cao unit cell structures. Alterations in the angle of rotation
et al. performed numerical simulations and theoretical influence these mechanical properties, as evidenced by
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analyses to systematically explore the dynamic mechanical findings that demonstrate a notable correlation between
properties of modified rhombic dodecahedron porous compressive stress and the maximum angle of rotation,
structures, suggesting that optimizing parameters can indicating a strong interaction. Several researchers have
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enhance their dynamic performance. It has also been explored the effects of rotation angle on the mechanical
reported that the dynamic fatigue strength of topologically properties of helical structures using a bionic design
optimized porous structures significantly exceeds that approach, revealing variations in SEA in response to
of rhombic dodecahedron structures composed of the changes in rotation angle. However, there has been
same metal and exhibiting identical porosity levels. limited research on the influence of rotation angle on the
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Furthermore, Kim et al. utilized a multiscale approach mechanical behavior of lattice structures under dynamic
to evaluate the impact resistance of porous aluminum loading conditions. Therefore, it is imperative to conduct
foam-filled components, demonstrating that these porous a comprehensive investigation into how the rotation angle
materials outperform hollow tube structures of equivalent affects the mechanical properties and energy absorption
weight in terms of energy absorption. While dodecahedral of lattice porous structures in dynamic scenarios. This
(Dodeca) and octahedral (Octa) structures are prevalent study further advances existing research on the dynamics
in porous materials and have attracted attention, existing of porous lattice structures by providing new insights into

Volume 4 Issue 2 (2025) 2 doi: 10.36922/MSAM025130019