Hypervelocity impact response and equation-of-state characterization of selective laser melted AlSi10Mg alloy

With the advancement of 3D printing technology, there is a growing trend toward employing intricate selective laser melted (SLM) lightweight lattice structures as hypervelocity impact-resistant devices, potentially replacing traditional Whipple shield configurations. However, systematic analysis of the hypervelocity mechanical performance of SLM-manufactured materials—particularly the widely used AlSi10Mg aluminum alloy—remains insufficient. To investigate the dynamic response mechanisms of SLM AlSi10Mg aluminum alloy under hypervelocity impact, this study systematically quantifies the material's mechanical behavior and pore defect effects through integrated porosity-incorporated numerical simulations and hypervelocity shock compression experiments. A quantitative predictive model correlating porosity with shock wave propagation was established through micro-CT-based pore reconstruction. The study identifies dual attenuation mechanisms mediated by pore networks, involving both energy dissipation through pore collapse and impedance mismatch effects at pore-matrix interfaces. These coupled mechanisms reduce shockwave velocity, attenuate pressure amplitude, and ultimately decrease the equation-of-state (EOS) parameters compared to those of defect-free theoretical values. Hypervelocity shock compression experiments were then conducted at pressures of 14.76 GPa-58.45 GPa, with maximum velocities exceeding 5 km/s, validating the reliability of numerical simulations and enabling the pioneering experimental determination of Hugoniot EOS parameters for SLM AlSi10Mg under hypervelocity conditions. The experimental results demonstrate that compared to conventional wrought aluminum alloys, the SLM material exhibits slight reductions in EOS parameters (1%-10%) alongside systematic degradation of compressive resistance. The scientific innovations of this work include quantitative elucidation of additive manufacturing (AM) defect-shockwave interactions through energy redistribution mechanisms; the pioneer experimental acquisition of Hugoniot EOS parameters for SLM aluminum alloys under extreme dynamic loading.