Numerical Homogenization and Directional Stiffness of Powder Metallurgically Produced AlSi10Mg Foams

Study Overview

This study investigates the elastic behavior of AlSi10Mg foams fabricated via powder metallurgical methods using TiH₂ as a foaming agent. Nanoindentation-based characterization of the foam wall material was combined with mechanical compression testing and simulation-based numerical homogenization to determine both microscopic and macroscopic Young’s moduli. High-resolution X-ray microscopy (XRM) data of three representative specimens were used to generate finite element meshes for computing directional stiffness properties.

Dataset Overview

The dataset consists of five main components:

1. High-resolution X-ray microscopy (XRM) data (XRM_Specimen_*.zip)

2. Compression experiment data (compression_experiment)

3. Numerical homogenization data (numerical_homogenization)

4. Raw mechanical testing data (Data_compression_tests.xlsx)

5. Microstructural characterization data (microstructural_characterization.zip)

All measurements are given in millimeters (mm), stiffness values in MPa, and forces in N.

High-Resolution X-ray Microscopy (XRM) Data

The XRM_Specimen_*.zip files contain tomography image stacks of three foam specimens.

• Imaging: Zeiss Xradia 520 Versa

• Parameters: 140 kV, 10 W, 0.037 s exposure, 3201 projections, voxel size 15.1 µm isotropic

• Export: reconstructed with Zeiss Reconstructor, saved as DICOM stacks via Zeiss Data Explorer

Structure:

• Specimen A → 8 parts

• Specimen B → 10 parts

• Specimen C → 9 parts

• Each archive contains max. 100 DICOM slices → to restore, extract all parts into one folder.

Compression Experiment Data (compression_experiment)

Contains processed simulation and analysis of the compression tests.

• segmented_3D_volume.npy – volumetric data

• linearelastic_pressure_test.h5/.xdmf – deformation fields under uniaxial load (viewable in ParaView)

• linearelastic_pressure_test_graphs.txt – tabular force–displacement records:

  • Col 1: applied displacement

  • Col 3: reaction force X

  • Col 4: reaction force Y

Raw Mechanical Testing Data (Data_compression_tests.xlsx)

Excel data of the quasistatic compression tests described in Section 2.4 Mechanical Testing of the publication.

• Testing: ZwickRoell BT1-FR2.5TN.D14 system, ±2.5 kN load cell

• Measurement: Limess Q400 3D-DIC system

• Loading: displacement-controlled, v = 0.001 mm/s

• Test sequence: flattening up to 80 N → cycles to 80 N and 350 N along x/y orientations

• Sampling: 10 Hz (80 N), 2 Hz (350 N), 5 Hz for specimen C

This file provides synchronized stress–strain and reaction force data for experimental validation.

Microstructural Characterization (microstructural_characterization.zip)

This dataset contains the characterization of the AlSi10Mg foam bulk material. It includes nanoindentation-based determination of micro- and nanohardness as well as electron diffraction spectroscopy (EDS) mapping of the microstructure.

1. Nanoindentation (UNAT Asmec Nanoindenter)

• Standard: EN ISO 14577

• Indentations performed using a UNAT Nanoindenter (Asmec).

• Force-controlled half-sine loading with a duration of 14 s.

• Two circular patterns at different positions within the foam walls, each containing 153 indents, arranged in concentric circles with increasing radius.

• Analysis carried out using ZHN InspectorX software; all datasets drift corrected.

• Files included:

  • Individual loading curves: stored in separate Excel files (VP3_S10_00529_XXXX.xlsx).

  • Aggregated data: combined and drift-corrected results in Circle3_153_corr and Circle4_153_corr.

• Relevant data columns (used in the publication):

  • Relative position (X, Y)

  • Maximum indentation depth h

  • Indentation hardness H

  • Young’s modulus E

2. Electron Diffraction Spectroscopy (EDS)

• Performed with a Philips XL40 electron microscope.

• Mapping at 430× magnification with 10 kV acceleration voltage.

• Provides elemental and structural mapping of the microstructure, complementing the nanoindentation results.

Numerical Homogenization Data (numerical_homogenization)

Contains simulation-based homogenization results for full specimens (1-part) and quarter models (4-part).

• Chom.json – homogenized stiffness tensor

• E_moduli.json – directional Young’s moduli (x→11, y→22, z→33, min/max)

• G_moduli.json – shear moduli

• *_dec_mesh.vtk – mesh visualization

• *_point_cloud.png – graphical representation

• write_e33_to_mesh.h5/.xdmf – stiffness mapped onto mesh

Notes

• Lengths: mm

• Stiffnesses: MPa

• Forces: N

• XRM voxel size: 15.1 µm³

• Subvolume labels: denote extraction coordinates (e.g., subvolume_x81_y90)