Three-point bending behavior of aluminum foam sandwich with steel panel

Static three-point bending tests of aluminum foam sandwiches with glued steel panel were performed. The deformation and failure of sandwich structure with different thicknesses of panel and foam core were investigated. The results indicate that the maximum bending load increases with the thickness of both steel panel and foam core. The failure of sandwich can be ascribed to the crush and shear damage of foam core and the delamination of glued interface at a large bending load, The crack on the foam wall developed in the melting foam procedure is the major factor for the failure of foam core. The sandwich structure with thick foam core and thin steel panel has the optimal specific bending strength. The maximum bending load of that with 8 mm panel and 50 mm foam core is 66.06 kN.

Preparation of Aluminum Foam Sandwich by Rolling-bonding/Powder Metallurgy Foaming Technology

Aluminum foam sandwich was prepared by rolling-bonding/powder metallurgical foaming technology, and the effects of rolling on bond strength of face sheet/powders and powder density were studied. Moreover, the foaming agent, TiH2, was heat treated and a certain amount of Mg was added into powder in an attempt to understand how the stability and uniformity of foam was improved. The experimental results show that the foaming precursors with ideal quality were obtained by rolling-bonding process. When rolling reduction is 67%, the consistency of powders reach to 99.87%. Throughout consideration of the bonding of face sheet/ core layer powders and deformation characteristic of powders, the optimum rolling reduction is 60%-70%. Cracks and drainage during foaming were inhibited by heat treatment of foaming agent TiH2 and the addition of a certain amount of Mg. The optimum heat treatment way of TiH2 is that heat preserving 1 hour at 450 ℃; the amount of adding Mg is 1wt%.

Dynamic and quasi-static compressive performance of integral-forming aluminum foam sandwich

Strain rate sensitivity and deformation mechanism of integral-forming aluminum foam sandwich(IFAFS)under quasi-static and dynamic compression were investigated.Split Hopkinson pressure bar experiments with high-speed video cameras were conducted to analyze strain rate dependency and actual deformation mechanism of IFAFS.X-ray microtomography technique(Micro-CT)based on 3D finite element(FE)was used to study stress and plastic strain contours of IFAFS sample and to predict stress distribution and deformation history under both dynamic and quasi-static loadings.Micro-inertia effect of typical cell structures was quantitatively analyzed by FE simulation.The results showed that IFAFS is sensitive to strain rate where the deformation mode under dynamic loading is different from that observed under quasi-static loading.With strain rate increasing,good metallurgical bonding of face sheet and foam core layer contributed to improving the elastic modulus and peak stress of IFAFS.Furthermore,finite element model confirmed that micro-inertia effect of IFAFS can be ignored during dynamic loading.

Study on the Interface Bonding and Bending Fatigue Properties of Aluminum Alloy Foam Sandwich

Foam materials have many attractive properties because of their low-weight and cell structure. By sandwiches with an aluminum-foam core, it is possible to obtain higher structural stiffness and rigidity, maintain stability against buckling and additionally make use of the high energy dissipation capability of the bare foams. The most obvious and straightforward one is adhesive bonding of pre-fabricated aluminum foams and metal face sheets. A new manufacture processing is proposed for preparation of aluminum alloy foam sandwich, ie., Al-plate/mixed element powder/ Al-plate are sandwich rolled together by a large reduction in pass, which is then foamed in heating furnace to manufacture end-use product. Aluminum alloy foam sandwich is obtained in this experiment. The experimental results showed that the process of rolling interface belongs to mechanical bonding, whose mechanism is film theory. While interface bonding belong to metallurgy bonding in the process of foaming, Al atom interdiffused in the interface, and no new phase was generated in the foaming process of aluminum face sheet/powders precursor. Bending fatigue test results showed that the bonding force of the foamed sandwich interface is very high, in fatigue test fracture occurred in the whole foam aluminum sandwich panels and Al/foam core interface was not laminated.

Three-point bending performance of a new aluminum foam composite structure

A new composite structure based on aluminum foam sandwich and fiber metal laminate was proposed. A layer of glass fiber was provided at the interface between the metal panel and the aluminum foam core in this composite structure, using adhesive technology to bond the materials together by organic glue in the sequence of metal panel, glass fiber, aluminum foam core, glass fiber and metal panel. The experimental results show that the new composite structure has an improved comprehensive performance compared with the traditional aluminum foam sandwiches. The optimized parameters for the fabrication of the new aluminum foam composite structure with best bending strength were obtained. The epoxy resin and low porosity aluminum foams are preferred, the thickness of aluminum sheets should be at least 1.5 mm, and the type of glass fiber has little effect on the bending strength. The main failure modes of the new composite structures with two types of glues were discussed.

泡沫铝夹芯板重复击穿塑性响应及失效破坏

文中基于泡沫铝夹芯板的重复冲击实验,研究了冲头形状对夹芯板塑性响应及失效破坏的影响,并分析了其变形累积和能量耗散特性.结果表明:冲头直径与夹芯板边长比α直接影响夹芯板的变形模式,进而影响夹芯板的失效破坏模式.当α为0.2时,夹芯板主要产生局部凹陷,芯层通过局部压缩耗散能量,正面板首先发生破坏;当α达到0.4时,夹芯板主要产生整体弯曲和拉伸,芯层通过整体压缩耗散能量,背面板首先发生破坏.α越大,碰撞力峰值越大,碰撞时间越短,夹芯板的抗击穿次数越大.冲击能量越大,夹芯板在重复冲击下的能量恢复系数越小.

泡沫铝复合结构的制备研究进展与展望

泡沫铝是一种含有大量孔洞的多功能多孔金属材料,具备减震吸能、电磁屏蔽、隔热、阻尼、降噪等特性。由于其力学性能和耐腐蚀性能较差,研究人员多以密实金属材料作为面板或外壁提升泡沫铝的综合性能。泡沫铝夹芯板结构和泡沫铝填充管结构作为泡沫铝复合结构的两种形式,具有显著的吸能特性与结构强度。现如今,泡沫铝复合结构因生产效率低、产品尺寸小、界面结合强度差以及制备成本高等问题,其快速发展与行业推广受到了限制。首先综述了有关泡沫铝复合结构的制备方法,包括泡沫铝夹芯板结构的胶粘连接、螺栓连接、焊接连接及粉末冶金连接等方法,泡沫铝填充管结构的原位制备法和非原位制备法,并在此基础上介绍了泡沫铝复合结构的力学性能以及不同制备方法的局限性。最后,简要分析了泡沫铝复合结构在土木工程领域应用的可行性,并对其进行了总结与展望。

泡沫铝夹芯板的三点弯曲疲劳性能

为探讨夹芯板结构准静态下的弯曲失效模式和疲劳性能,以304不锈钢为面板,7050铝合金基体闭孔泡沫铝为芯层,组成泡沫铝夹芯板结构。基于三点弯曲试验获得夹芯板结构损伤变形过程和静态峰值载荷。通过三点弯曲疲劳试验得到疲劳寿命和破坏形式,采用最小二乘法和极大似然法绘制夹芯板的S-N和P-S-N曲线,并进行对比分析。结果表明:夹芯板在静态加载时的弯曲失效与载荷-位移曲线相吻合;在疲劳加载时失效方式较为单一,90%的试件因芯层断裂而失效。夹芯板疲劳寿命随着面板厚度的增加而增加,当芯层密度从0.60 g/cm^(3)增加到0.73 g/cm^(3)时,疲劳寿命反而出现下降;当芯层密度为0.60 g/cm^(3),面板厚度为0.6 mm时,夹芯板结构对加载水平敏感度最低。研究结果为夹芯板结构工程应用提供了设计基础。

基于石墨涂层传热技术制备界面冶金结合泡沫铝夹芯板

提出一种通过石墨涂敷处理(GCT)泡沫铝夹芯板(AFS)前驱体来提高其在粉末冶金发泡过程中传热效率的新方法。研究不同传热方法的升温和膨胀特征以及对泡孔结构和抗弯性能的影响。结果表明,前驱体在采用GCT后,升温速度增加近2倍,这提高了AFS的膨胀率、改善了泡孔尺寸均匀性和外部面板形态。此外,在发泡后期阶段具有更加平稳的升温速率,这有助于提高泡孔圆度,并减少泡壁内微孔缺陷。这些改变使AFS的弯曲强度和吸能性能得以显著提高。值得注意的是,因为热传递速率不受板幅尺寸的影响,GCT技术在大尺寸AFS的生产中具有巨大潜力。

重复冲击载荷下泡沫铝夹芯壳的动态响应

通过数值模拟研究了泡沫铝夹芯壳在重复冲击载荷作用下的变形和能量耗散机理,分析了曲率半径、前后面板厚度分配、芯层厚度和冲击能量梯度对结构抗重复冲击性能和能量吸收能力的影响规律。结果表明:在重复冲击载荷作用下,泡沫铝夹芯壳结构的变形不断累积,前面板局部弯曲变形,芯层局部压缩,后面板整体弯曲变形。随着冲击次数的增加,冲击力峰值逐渐增大,冲击持续时间缩短,结构能量吸收能力降低,整体抗弯刚度增大。每次冲击能量相同时,泡沫铝夹芯壳结构曲率越大,能量吸收能力越强,同时前、后面板5次重复冲击后的中点挠度大于曲率较小的夹芯壳结构。5次重复冲击载荷作用下,前面板厚度较大且后面板厚度较小时,结构的比吸能较低,但后面板中点挠度较小。泡沫铝芯层厚度越大,结构的后面板挠度越小,但总比吸能降低。3种不同梯度的冲击能量作用下,递增能量工况下结构的吸能最多,前、后面板的挠度较大,递减能量工况下结构的吸能最少,前、后面板的挠度较小。

EXPERIMENTAL AND NUMERICAL STUDIES OF THE ANTI-PENETRATION PERFORMANCE OF SANDWICH PANELS WITH ALUMINUM FOAM CORES

Effects of face-sheet thickness and core thickness of sandwich panels, and shape of projectiles on the penetration resistance of sandwich panels were discussed, while typical pen- etration failure modes were presented. It was shown that the anti-penetration performance of sandwich panels was enhanced with the increase of face-sheet or core thickness; The penetration resistance of sandwich panels was shown to be strongest to blunt-shaped projectile impacts, weaker to hemispherical-nose-shaped projectile impacts, and weakest to conical-shaped projectile impacts. The corresponding numerical simulation was carried out using the finite element code LS-DYNA V970. Numerical results showed that the penetration time decreased with the increase of projectile impact velocity.

泡沫铝夹芯板研究进展

泡沫铝作为特殊的结构和功能材料具有广泛的应用潜力,但因其本身强度较低而受到很大限制,通常将泡沫铝作为芯层,将致密金属板作为面板制成夹芯结构使用,以期实现材料在载荷下的最佳力学性能。泡沫铝夹芯板具有轻质、高比刚度和比强度等特殊性能,在航空航天、军工、建筑、交通等领域拥有广阔的应用前景。泡沫铝夹芯板是由面板和芯层组成的一种特殊复合材料,综合了泡沫铝和面板的优点,目前主要制备方法有胶结连接、表面热喷涂法、焊接连接、热压-粉末冶金发泡法。

泡沫铝夹芯结构冲击动力学研究进展

为全面了解泡沫铝夹芯结构在冲击作用下的防护性能,分析国内外对泡沫铝夹芯结构抗冲击性能的研究现状,从解析模型、数值仿真与实验研究三个方面进行分类论述,总结研究方法及相关内容,并对今后的研究方向作了展望。

泡沫铝夹芯圆筒抗爆性能研究

在验证了所用方法有效性的基础上,采用有限元软件LS-DYNA分析了重量相同、由A3钢和闭孔泡沫铝制成的夹芯圆筒与由A3钢制成的实体圆筒在3种不同爆炸载荷作用下的动力响应,同时分析了5种不同夹芯圆筒的抗爆性能。结果表明,在相同爆炸载荷的条件下,无论是在变形还是在能量吸收方面,夹芯圆筒都优于相同重量的实体圆筒;对于夹芯圆筒,内面板厚度应不大于外面板厚度,这样能在降低夹芯圆筒整体变形的同时发挥泡沫铝芯层的吸能优势。

滚石冲击闭孔泡沫铝夹芯板耗能缓冲机理研究

在山区构筑物外表面覆盖一层缓冲材料能有效减小滚石冲击危害,达到保护工程结构的目的。为此,将泡沫铝作为一种耗能缓冲材料引入滚石灾害冲击领域,并将其与钢板组合为夹芯板结构,采用静力压载试验及动力有限元对滚石冲击泡沫铝夹芯板动力响应进行分析,揭示泡沫铝夹芯板耗能缓冲作用机理。结果表明:泡沫铝及夹芯结构在进入屈服强度后有较宽的耗能缓冲平台,可吸收大量冲击能量;同时夹芯板结构可有效降低被保护物结构挠度变形,伴随夹芯钢板厚度不断增大,垫层冲击坑深度不断降低,被保护结构中心点变形有较明显下降,但过大的钢板厚度使得泡沫铝夹芯板整体刚度增强,反而不利于泡沫铝夹芯板能量耗散。因此,在泡沫铝缓冲垫层结构设计时,应综合考虑被保护物结构所容许的变形量及承受冲击力双重控制指标。

包套轧制粉末冶金法制备泡沫铝三明治板

以空气雾化的AlSi12合金粉、镁粉和氢化钛粉末为原料,采用包套轧制法成功制备出了泡沫铝三明治板材.利用300 dpi扫描仪、扫描电镜(SEM)和显微硬度仪等检测方法系统比较了复合轧制和包套轧制方法对制备前驱体的宏观形貌和界面结合及其泡孔结构的影响,结果表明:包套轧制可以有效阻止面板材料裂纹的扩展,获得完整的和致密度均匀的预制坯,并能实现面板芯材的有效结合,最终获得泡孔结构完整和均匀的泡沫铝三明治板.

泡沫铝夹芯板的制备技术

泡沫金属是一类具有低密度以及新奇的物理、力学、电学、声学等特殊性能的新型材料。而泡沫铝的潜在用途之一是作为泡沫铝夹芯板的芯材使用。详细介绍了制备泡沫铝夹芯板的不同方法,如胶粘法、超声焊接法、激光协助发泡法、扩散焊接法、面板与预制材料轧制-包覆法和粉末复合轧制法等。通过比较,在国内粉末复合轧制法工艺简单,是最有希望适合高温作业和大批量生产的方法。

轧制复合-粉末冶金发泡工艺制备泡沫铝夹心板

针对目前泡沫铝夹心板制备工艺中存在的主要问题，将轧制复合技术应用于可发泡复合板的制备，以获得更高的芯层粉末致密度与界面结合强度．研究结果表明，预压成型后的芯层粉体通过轧制过程能够同钢面板实现牢固的初结合，轧后芯层粉末的致密度明显高于热压复合板，粉末颗粒间呈紧密的层片状结构，为发泡过程创造了有利条件．综合考虑界面结合强度、芯层粉末致密度及轧制缺陷等因素，轧制压下率应控制在60％～70％为宜．复合板在适宜的发泡工艺下可以获得理想的泡沫体结构，最佳发泡温度为620～640℃，发泡时间为8-10min．发泡后在界面上生成了厚度均约为10μm的金属间化合物FeAl3及Fe/Al固溶体，无脆性金属间化合物Fe2Al5生成，界面形成了理想的冶金结合．

泡沫铝三明治板的研究与应用进展

泡沫铝三明治板(Aluminum foam sandwich,AFS)是基于泡沫铝材料开发的一类材料-结构一体化的先进多孔复合结构。AFS是交通运输、建筑以及航空航天等装备结构轻量化的重要材料,具有广阔的应用前景。概述了AFS的几类制备技术的基本原理和研究现状,着重分析了复合预制体制备、合金成分、AFS发泡成型工艺等关键环节中存在的理论和技术难点。介绍了AFS作为结构材料和功能材料的典型应用案例;最后总结提出了AFS材料研究和工程化技术开发的关键点与突破途径。

爆炸载荷下泡沫铝夹芯板变形与破坏模式的实验研究

系统地开展了爆炸载荷作用下泡沫铝夹芯板变形与破坏的实验研究,获得了冲量45.6 N·s、76.2 N·s、104.6 N·s、131.7 N·s、183.6 N·s 5种不同爆炸载荷作用下泡沫铝夹芯板背面板中心点的变形挠度,给出了泡沫铝夹芯板前面板、泡沫铝芯体和背面板在不同爆炸载荷作用下的变形与破坏模式,分析了泡沫铝芯体产生的剪切断裂和拉伸断裂两种不同机理。研究结果表明,泡沫铝芯体呈现"渐进式"压缩变形,泡沫铝夹芯板背面板中心点的变形挠度与爆炸冲量之间近似满足二次关系。