Investigation into quasi-static compression behaviors of AlSi10Mg closed-cell/semi-closed-cell Kelvin foams

To systematically elucidate the deformation evolution of Kelvin foams under multiple parameters (relative density, unit cell layer number, relative pore size) and determine the optimal unit cell layer-relative pore size configuration for maximum energy absorption at any relative density, this study conducted a comprehensive investigation. A semi-closed-cell AlSi₁₀Mg Kelvin foam was 3D printed, followed by quasi-static compression experiments; ABAQUS simulations were used to examine key parametersʼ effects on closed/semi-closed Kelvin foamsʼ compressive behaviors. Results show: increasing unit cell layers and relative density shifts unit cell deformation from quadrilateral to hexagonal faces; lower unit cell layer number with higher relative density promotes fracture, forming semi-unit cell interlocking stacks, while high unit cell layers suppress fractures, leading to flattened whole-unit-cell layered stacks. For closed-cell Kelvin foams at any relative density, energy absorption first increases then stabilizes with unit cell layers (stabilizing at 5 layers for 5 % relative density, 10 layers for 10 %-25 % relative density). At any relative density and unit cell layer, energy absorption rises then falls with increasing relative pore size, peaking at 1/5. This work systematically clarifies closed/semi-closed Kelvin foamsʼ deformation behaviors, guiding their economical preparation and application.