Page 112 - MSAM-4-2

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

properties, as well as corrosion performance 31,56,57 for all samples were produced using identical materials and
AlSi10Mg and other alloys. Figures 6D and E further show processing parameters. Accordingly, in this study, consistent
the SEM microstructure of LPBF-fabricated AlSi10Mg LPBF parameters resulted in comparable material density
samples at low and high magnifications. The SEM images and surface roughness across all structures. Consequently,
reveal three typical distinct microstructural regions: the the discrepancies in mechanical behavior identified in this
melt pool region, the coarse-grain zone, and the heat- investigation are primarily attributed to variations in unit
affected zone (Figure 6D). The microstructure exhibits a cell structure, single-unit cell rotation angles, and porosity
significant presence of network-like cellular structures level. The subsequent section will examine the dynamic
enriched with silicon (Figure 6E), which is consistent with response of these structures, focusing on the effects of
the findings reported by Liu et al. and other literature. varying impact energy levels, porosities, and single-unit cell
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Specifically, during LPBF of AlSi10Mg, rapid solidification rotation angles on impact performance.
promotes silicon segregation along the cellular boundaries
of the α-Al matrix, forming a silicon-rich eutectic 3.2.1. Effects of varying impact energies on fracture
network. Variations in the size and morphology of behavior
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this network have been shown to significantly influence Distinguishing the effect of varying impact energies on
mechanical performance. 59 the dynamic mechanical behavior of porous structures
is critical for understanding their transient impact
3.2. Dynamic response analysis resistance and potential applications. In this study,
4
Based on the above discussion, the X-CT results reveal that the Dodeca-A structure with 80% porosity (Dodeca-A
the actual volume and dimensions of the samples fabricated P80) was first selected for the M1 and M2 impact tests
through LPBF closely align with the theoretical design (Table 2) to systematically investigate its mechanical
specifications. Furthermore, densification measurements response under varying impact loading conditions.
confirm the successful fabrication of LPBF-built AlSi10Mg Force-displacement and energy-displacement curves
porous structures with varying unit cell rotations and were analyzed to characterize the deformation and
similar microstructures. The influence of structural porosity energy absorption behavior of the structure, offering key
errors and material defects induced by the LPBF process insights into its damage evolution, as shown in Figure 7A
on mechanical behavior is not considered in this study, as and B, respectively. The results indicate that the linear

A B C

D E

Figure 6. Quality and microstructure of material manufacturing (A) Macroscopic surface of the LPBF-built AlSi10Mg lattice strut regions observed using
scanning electron microscopy. Scale bar: 200 μm, magnification: 75×. (B) MP tracks and morphology, exhibiting few irregular pores. (C) Schematic diagram
of the scanning strategy used in LPBF. (D) Microstructure of the sample at low magnification. Scale bar: 10 μm, magnification: 2000×. (E) Microstructure
of the sample at high magnification, highlighting network-like cellular structures enriched with Si. Scale bars: 500 nm and 2 μm, magnification: 22000×,
9500×
Abbreviations: CGZ: Coarse-grain zone; HAZ: Heat-affected zone; MP: Melt pool; LPBF: Laser powder bed fusion; Si: Silicon

Volume 4 Issue 2 (2025) 8 doi: 10.36922/MSAM025130019