Chebyshev polynomial-based Ritz method for thermal buckling and free vibration behaviors of metal foam beams

This study presents the Chebyshev polynomials-based Ritz method to examine the thermal buckling and free vibration characteristics of metal foam beams.The analyses include three models for porosity distribution and two scenarios for thermal distribution.The material properties are assessed under two conditions,i.e.,temperature dependence and temperature independence.The theoretical framework for the beams is based on the higher-order shear deformation theory,which incorporates shear deformations with higher-order polynomials.The governing equations are established from the Lagrange equations,and the beam displacement fields are approximated by the Chebyshev polynomials.Numerical simulations are performed to evaluate the effects of thermal load,slenderness,boundary condition(BC),and porosity distribution on the buckling and vibration behaviors of metal foam beams.The findings highlight the significant influence of temperature-dependent(TD)material properties on metal foam beams'buckling and vibration responses.

Compression properties of cost-efficient porous expanded clay reinforced AA7075 syntactic foams fabricated by industrial-oriented die casting technology

In today’s manufacturing industries,hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and anti-pollution.At this point,aluminum syntactic foams(ASFs)are new-generation engineering composites and come into the upfront as a problem-solver.Owing to their features like low density,sufficient elongation,and perfect energy absorption ability,these advanced foams have been considerably seductive for many industrial sectors nowadays.In this study,an industrial-oriented automatic die casting technology was used for the first time to manufacture the combination of AA7075/porous expanded clay(PEC).Micro evaluations(optical and FESEM)reveal that there is a homogenous particle distribution in the foam samples,and inspections are compatible with the other ASF studies.Additionally,T6 aging heat treatment was operated on one half of the produced foams to explore the probable impact of aging on the compressive responses.Attained results show that PEC particles can be an alternative to expensive hollow spheres used in the previous works.Besides,a favorable relationship is ascertained between the aging treatment and mechanical properties such as compression strength and plateau strength.

ULTRALIGHT POROUS METALS:FROM FUNDAMENTALS TO APPLICATIONS

Over the past few years a number of low cost metallic foams have been produced and used as the core of sandwich panels and net shaped parts.The main aim is to develop lightweight structures which are stiff,strong,able to absorb large amount of energy and cheap for application in the transport and construction industries.For example,the firewall between the engine and passenger compartment of an automobile must have adequate mechanical strength,good energy and sound absorbing properties,and adequate fire retardance.Metal foams provide all of these features,and are under serious consideration for this applications by a number of au- tomobile manufacturers(e.g.,BMW and Audi).Additional specialized applications for foam-cored sandwich panels range from heat sinks for electronic devices to crash barriers for automobiles,from the construction panels in lifts on aircraft carriers to the luggage containers of aircraft,from sound proofing walls along railway tracks and highways to acoustic absorbers in lean premixed combustion chambers.But there is a problem.Before metallic foams can find a widespread application,their basic properties must be measured,and ideally modeled as a function of microstructural details,in order to be included in a design.This work aims at reviewing the recent progress and presenting some new results on fundamental research regarding the mi- cromechanical origins of the mechanical,thermal,and acoustic properties of metallic foams.

Mechanical Property of Foamed Metal

A comprehensive study on the mechanical behavior of foamed metals was demonstrated.The relationship among their mechanical properties,preparation method,porosity and the structure was briefly studied as well.

Development in applications of porous metals

Applications of porous metal materials are reviewed so far. These applications deal with filtration and separation, energy absorption, electrode matrix, fluid distribution and control, heat exchangers, reaction materials, constructional materials, electromagnetic shielding, biomaterials and so on. All these are expected to promote the improvement of the property and structure for porous metals.

Elasto-plastic constitutive model of aluminum alloy foam subjected to impact loading

A multi-parameter nonlinear elasto-plastic constitutive model which can fully capture the three typical features of stress-strain response, linearity, plasticity-like stress plateau and densification phases was developed. The functional expression of each parameter was determined using uniaxial compression tests for aluminum alloy foams. The parameters of the model can be systematically varied to describe the effect of relative density which may be responsible for the changes in yield stress and hardening-like or softening-like behavior at various strain rates. A comparison between model predictions and experimental results of the aluminum alloy foams was provided to validate the model. It was proved to be useful in the selection of the optimal-density and energy absorption foam for a specific application at impact events.

Indentation of sandwich beams with metal foam core

The quasi-static indentation behavior of sandwich beams with a metal foam core was investigated. An analytical model was developed to predict the large deflections of indention of the sandwich beams with a metal foam core subjected to a concentrated loading. The interaction of plastic bending and stretching in the local deformation regions of the face sheet was considered in the analytical model. Moreover, the effects of the shear strength of the foam core on the indentation behavior were discussed in detail. The finite element simulations were preformed to validate the theoretical model. Comparisons between the analytical predictions and finite element results were conducted and good agreement was achieved. The results show that the membrane force dominates indentation behavior of the sandwich beams when the maximum deflection exceeds the thickness of the face sheet.

Modeling of the role of defects in sintered FeCrAlY foams

The metal sintering approach offers a costeffective means for the mass-production of open-cell foams from a range of materials, including high-temperature steel alloys, which offer novel mechanical and acoustic properties. In a separate experimental study, the mechanical properties of open-celled steel alloy （FeCrA1Y） foams have been characterized under uniaxial compression and shear loading. Compared to predictions from established models, a significant knockdown in material properties was observed. This knockdown was attributed to the presence of defects throughout the microstructure that result from the unique fabrication process. In the present paper, the microstructure of sintered FeCrA1Y foams was modeled by using a finite element （FE） model. In particular, microstructural variations were introduced to a base lattice, and the effects on the strength and stiffness calculated. A range of defects identified under scanning electronic microscope （SEM） imaging were considered including broken ligaments, thickness variations, and pore blockages, which are the three primary imperfections observed in sintered foams. The corresponding levels of defect present in the material were subsequently input into the FE model, with the resulting predictions correlating well with experimental data.

Mechanical characterization of the role of defects in sintered FeCrAIY foams

Open celled metal foams fabricated through metal sintering are a new class of material that offers novel mechanical and acoustic properties. Previously, polymer foams have been widely used as a means of absorbing acoustic energy. However, the structural applications of these foams are limited. The metal sintering approach offers a costeffective means for the mass-production of open-cell foams from a range of materials, including high-temperature steel alloys. In this first part of two-paper series, the mechanical properties of open-celled steel alloy （FeCrA1Y） foams were characterized under uniaxial compression and shear loading. Compared to predictions from established models, a significant knockdown in material properties was observed. This knockdown was attributed to the presence of defects throu- ghout the microstructure that result from the unique fabrication process. Further in situ tests were carried out in a SEM （scanning electronic microscope） in order to investigate the effects of defects on the properties of the foams. Typically, the onset of plastic yielding was observed to occur at defect locations within the microstructure. At lower relative densities, ligament bending dominates, with the deformation initializing at defects. At higher relative densities, an additional deformation mechanism associated with membrane elements was observed. In the follow-up of this paper, a finite element model will be constructed to quantify the effects of defects on the mechanical performance of the opencell foam.

Electroless copper plating on microcellular polyurethane foam

In order to obtain substrates with good conductive foam for high porosity foam metal materials used in the metal electrodes,the technique of electroless copper plating on the microcellular polyurethane foam with pore size of 0.3 mm was investigated.The main factors affecting the deposition rate such as the solution composition,temperature,pH value and adding ultrasonic were explored.The results show that the optimum process conditions are CuSO4 16 g/L,HCHO 5 mL/L,NaKC4H4O6 30 g/L,Na2EDTA 20 g/L,K4Fe(CN)6 25 mg/L,pH value of 12.5-13.0 and temperature of 40-50℃.Under these technical conditions, the process has excellent bath stability.Adding ultrasonic on the process can elevate the deposition rate of copper by 20%-30%.The foam metal material with a porosity of 92.2%and a three-dimensional network structure,was fabricated by electro-deposition after the electroless copper plating.

Effects of porosity and pore size on the compressive properties of closed-cell Mg alloy foam

In our current work,AZ31 magnesium alloy foams with closed-cell were successfully fabricated by melt foaming method using Ca and CaCO3 as thickening and blowing agent,respectively.The influences of porosity and pore size on the quasi-static compressive properties of the foams were systematically investigated.The results showed that the yield strength,energy absorption capacity and ideality energy absorption efficiency were decreased with the increase in porosity.However,specimens with porosities of 60%,65%and 70%possessed similar total energy absorption capacity and ideality energy absorption efficiency.Meanwhile,experimental results showed that mean plateau strength of the foams was increased first and then decreased with increase in mean pore size.In addition,energy absorption capacities were almost the same in the initial stage,while the differences were obvious in the middle stage.From the engineering point of view,the specimens with mean pore size of 1.5 mm possess good combination of mean plateau strength and energy absorption characteristics under the present conditions.

A plastic indentation model for sandwich beams with metallic foam cores

Light weight high performance sandwich composite structures have been used extensively in various load bearing applications.Experiments have shown that the indentation significantly reduces the load bearing capacity of sandwiched beams.In this paper,the indentation behavior of foam core sandwich beams without considering the globally axial and flexural deformation was analyzed using the principle of virtual velocities.A concisely theoretical solution of loading capacity and denting profile was presented.The denting load was found to be proportional to the square root of the denting depth.A finite element model was established to verify the prediction of the model.The load-indentation curves and the profiles of the dented zone predicted by theoretical model and numerical simulation are in good agreement.

Production and fluoride treatment of Mg-Ca-Zn-Co alloy foam for tissue engineering applications

Highly porous Mg-Ca-Zn-Co alloy scaffolds for tissue engineering applications were produced by powder metallurgy based space holder-water leaching method.Mg-Ca-Zn-Co alloy foam can be used as a scaffold material in tissue engineering.Carbamide was used as a space holder material.Fluoride conversion coating was synthesized on the alloy by immersion treatment in hydrofluoric acid(HF).Increasing Zn content of the alloy increased the elastic modulus.Ca addition prevented the oxidation of the specimens during sintering.Electrochemical corrosion behaviour of the specimens was examined in simulated body fluid.Corrosion rate decreased with Zn addition from1.0%up to3.0%(mass fraction)and then increased.Mass loss of the specimens initially decreased with Zn addition up to about3%and then increased.Fluoride conversion coating increased the corrosion resistance of the specimens.

Mathematical modeling for dynamic stability of sandwich beam with variable mechanical properties of core

The paper is devoted to mathematical modelling of static and dynamic stability of a simply supported three-layered beam with a metal foam core. Mechanical properties of the core vary along the vertical direction. The field of displacements is for- mulated using the classical broken line hypothesis and the proposed nonlinear hypothesis that generalizes the classical one. Using both hypotheses, the strains are determined as well as the stresses of each layer. The kinetic energy, the elastic strain energy, and the work of load are also determined. The system of equations of motion is derived using Hamilton＇s principle. Finally, the system of three equations is reduced to one equation of motion, in particular, the Mathieu equation. The Bubnov-Galerkin method is used to solve the system of equations of motion, and the Runge-Kutta method is used to solve the second-order differential equation. Numerical calculations are done for the chosen family of beams. The critical loads, unstable regions, angular frequencies of the beam, and the static and dynamic equilibrium paths are calculated analytically and verified numerically. The results of this study are presented in the forms of figures and tables.

Sound absorption performance of various nickel foam-base multi-layer structures in range of low frequency

Commercial3D reticular nickel foam and its composite structure were investigated on the sound absorption at200-2000Hz.The absorption performance of foam plates1?5layers(1-layer thickness:2.3mm;porosity:89%;average pore-diameter:0.57mm)was found to be poor,and could be improved by adding backed cavum or front perforated thin sheet.The absorption coefficient could reach about0.4at1000-1600Hz for the composite structure of5-layer foam with a backed5mm-thick cavum,and even0.68at about1000Hz for that of2-layer foam with the same cavum and a perforated plate closely in front of the foam.

Microstructural examination and mechanical properties of replicated aluminium composite foams

Open-cell aluminium foams can be produced with the structural replication of dimensional accuracy from polymeric foam patterns through a pressure infiltration casting process.The strength of open-cell foam is much less than that of the closed-cell counterpart,and thereby subjects to mainly functional applications.An improvement in mechanical properties of the foams can be implemented with the addition of ceramic particles.In the present study,the composite foams were produced using AC3A alloy added with varying contents of SiC particles.The resultant foams have ceramic particles embedded in the alloy matrix and on the strut surface.Higher volume fraction of ceramic particles resulted in an increase in the compressive strength,energy absorption and microhardness of the foams.The improvement of these properties is due to the modification of the microstructure of the foams and the increased strength in the node and struts at which the ceramic particles reside.

Strain rate sensitivity of closed cell aluminium fly ash foam

With the increasing use of metal foams in various engineering applications, investigation of their dynamic behaviour under varying strain rate is necessary. Closed cell aluminium fly ash foam developed through liquid metallurgy route was investigated for its stress--strain behaviour at different strain rates ranging from 700 s^-1 to 1950 s^-1. The numerical model of split Hopkinson pressure bar （SHPB） was simulated using commercially available finite element code Abaqus/Explicit. Validation of numerical simulation was carried out using available experimental and numerical results. Full scale stress--strain curves wez＇e developed for various strain rates to study the effect of strain rate on compressive strength and energy absorption. The results showed that the closed cell aluminium fly ash foam is sensitive to strain rate.

Role of Composite Phase Change Material on the Thermal Performance of a Latent Heat Storage System: Experimental Investigation

Paraffin wax is a perfect phase change material(PCM)that can be used in latent heat storage units(LHSUs).The utilization of such LHSU is restricted by the poor conductivity of PCM.In the present work,a metal foam made of aluminium with PCM was used to produce a composite PCM as a thermal conductivity technique in PCM⁃LHSU and water was used as heat transfer fluid(HTF).An experimental investigation was carried out to evaluate the heat transfer characteristics of LHSU using pure PCM and composite PCM.The study included time⁃dependent visualization of the PCM during the melting and solidification processes.Besides,a thermocouple network was placed inside the heat storage to record the temperature profile during each process.Results showed that better performance could be obtained using composite PCM⁃LHSU for both melting and solidification processes.The melting time of composite PCM⁃LHSU was about 83%faster than that of a simple PCM⁃LHSU,and the percentage decreasing in the solidification time was about 85%due to the provision of metal foam.

Synthesis and characterization of Ti-Co alloy foam for biomedical applications

Highly porous Ti-Co alloy specimens for biomedical applications were synthesized by powder metallurgy based space holder technique. Ti alloys have high melting temperature and affinity for oxygen, which makes Ti alloys difficult to be processed. The Co addition reduces the melting temperature and Ti-Co alloy was sintered at lower temperatures. The electrochemical corrosion behaviour of the specimens was examined in the artificial saliva solution. The effects of Co content of the alloy, the p H value and fluoride concentration of the artificial saliva solution on the electrochemical corrosion properties of the specimens were investigated. The microstructure and mechanical properties of the specimens were examined. The electrochemical impedance spectroscopy results indicate that the corrosion resistance of the specimens decreases at high fluoride concentrations and low p H value. The defect density increases with increasing the fluoride concentration and decreasing the p H value of artificial saliva according to Mott-Schottky analysis.

Properties and corrosion behavior of Al based nanocomposite foams produced by the sintering-dissolution process

The properties orAl based nanocomposite metal foams and their corrosion behaviors were investigated in this study. For this, the composite metal foams with different relative densities （porosity） reinforced with alumina nanoparticles were prepared using a powder me- tallurgy-based sintering-dissolution process （SDP） and NaC1 particles were used as space holders. Then, the effect of nanoparticle rein- forcement and different amounts of NaC1 space holders （corresponding porosity） on the microstructure, morphology, density, hardness, and electrochemical specifications of the samples were investigated. It was found that as the relative density increased from 60% to 70%, the wall thickness increased from about 200 to 300 pro, which led to a decrease in pore size. Also, the addition of nanoparticle reinforcement and the increased relative density result in increasing metal foam hardness. Moreover, electrochemical test results indicated that increasing the A1203 content reduced the corrosion rate, but increasing the porosity enhanced it.