As far as the residue, my thoughts are that the temp of the molten aluminum, is well up into the combustion range upon the impact encounter with the other materials of the bullet. Aluminum is quite combustible, burns very hot, and under certain conditions will ignite as low as 1300* to 1500* F. So as these small fragments of the aluminum plate are traveling through the media stack they are on fire as well. Look at the char around the hole in card #1, and the heat discoloration on the aluminum plate around the holes. Once ignition takes place the aluminum burns at or above 3000* F. Neither lead or copper is likely to combust, steel however can ignite at just 1500*F if you are shooting mild steel targets.
As for test media, what about a piece of thick cow hide like from work boots or belts, or rubber from the sidewall of a tire. Maybe one piece in front of each card in the stack. I'm sure you are a good enough shot that one pair of boots from a thrift store could make 50 1" dia. medalions cut out with a hole saw with no centering bit; enough for 6 tests of 8 cards. You could try some dry and some soaked in water over night.