Page 115 - MSAM-4-2

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

indicate the ability of each structure to resist deformation, P90 demonstrates a ~7.22% increase in peak force over
with Dodeca-C exhibiting the highest resistance among the Octa-A P90. However, this advantage is offset by a notable
Dodeca structures at 80% porosity in Figure 9A, followed reduction in both total energy absorption and SEA, which
by Dodeca-B, whereas Dodeca-A demonstrates the lowest decline by ~11.7% and ~10.9%, respectively (Figure 10B).
resistance. Among the Octa structures in Figure 9C, Consequently, when considering the performance metrics
Octa-A P80 displays superior resistance compared to of the structures, Octa-A P90 is deemed superior despite
Octa-B P80. In addition, at this impact energy level, the its lower peak force. The observed performance variations
structure with 90% porosity in Figure 9B and D undergoes can be attributed to differences in load distribution and
rapid deformation and transitions to a dense state, whereas deformation mechanisms inherent to each design, which will
the structure with 80% porosity does not experience be investigated later through numerical simulation analysis.
this change. This distinction suggests the critical role Figure 11 compares the specific strength of Dodeca
of optimizing porosity in determining the mechanical and Octa structures at 80% porosity, revealing distinct
response of lightweight structures under impact loading. performance trends governed by topology-driven

Thus, further comparisons of the peak force, energy mechanical behavior. Among the Dodeca structures,
absorption, and SEA for various structures with 90% Dodeca-C P80 exhibits the highest specific strength,
porosity are presented in Figure 10. Among the Dodeca significantly surpassing both Dodeca-A P80 and Dodeca-B
structures in Figure 10A, Dodeca-B P90 exhibits the P80. This enhancement suggests that Dodeca-C’s single-unit
highest peak force at ~3.53 kN, representing a ~33.5% cell orientation architecture optimizes stress redistribution.
improvement over Dodeca-A P90. Following closely, In contrast, within the Octa series, Octa-A P80 exhibits
Dodeca-C P90 achieves a peak force of ~3.26 kN, indicating a higher specific strength than Octa-B P80, confirming
a ~23.5% enhancement compared to Dodeca-A P90. When that the single-unit cell orientation does not enhance the
evaluating energy absorption, both energy absorption and performance of Octa-B. Notably, both Octa structures
SEA metrics reveal significant performance differences outperform their Dodeca counterparts, indicating that
among the structures. The Dodeca-C P90 structure Octa lattice frameworks offer superior strength-to-mass
demonstrates substantial increases in both metrics compared ratios. The observed hierarchy in specific strength aligns
to the Dodeca-A P90, with enhancements of ~18.9% in closely with the energy absorption characteristics, where
total energy absorption and ~17.1% in SEA. In contrast, Dodeca-C and Octa-A emerge as the most mechanically
Dodeca-B P90 shows modest improvements, with increases efficient structures within their respective categories.
of only ~2.3% and ~1.7%, respectively. Although Dodeca-C
P90 does not have the highest peak force, its superior 3.2.3. Influence of unit cell orientation under high
energy absorption profile positions it as the best performer impact energy (248 J)
among the Dodeca P90 structures. The notable increase in The sustained energy absorption capacity of porous
energy absorption for Dodeca-C indicates that optimizing structures during high-impact events is also vital for
single-unit cell orientation can effectively enhance the applications that require enhanced impact resistance. This
balance between the strength and ductility of the Dodeca section presents the results of high-impact tests conducted
structures. For the Octa structures in Figure 10B, Octa-B on Dodeca P80 and Octa P80 structures exhibiting

A B

Figure 10. Peak force, energy absorption, and SEA under impact loading at an energy level of 124 J for various LPBF-built AlSi10Mg porous materials with
90% porosity. (A) Dodeca structures and (B) Octa structures
Abbreviations: Dodeca: Dodecahedral; Octa: Octahedral; SEA: Specific energy absorption; LPBF: Laser powder bed fusion

Volume 4 Issue 2 (2025) 11 doi: 10.36922/MSAM025130019