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.

Effects of cell wall property on compressive performance of aluminum foams

The effects of cell wall property on the compressive performance of high porosity, closed-cell aluminum foams prepared by gas injection method were investigated. The research was conducted both experimentally and numerically. Foam specimens prepared from conditioned melt were tested under uniaxial compressive loading condition. The cell wall microstructure and fracture were observed through optical microscope（OM） and scanning electron microscope（SEM）, which indicates that the cell wall property is impaired by the defects in cell walls and oxide films on the cell wall surface. Subsequently, finite element（FE） models based on three-dimensional thin shell Kelvin tetrakaidecahedron were developed based on the mechanical properties of the raw material and solid material that are determined by using experimental measurements. The simulation results show that the plateau stress of the nominal stress-strain curve exhibits a linear relationship with the yield strength of the cell wall material. The simulation plateau stress is higher than the experimental data, partly owing to the substitution of solid material for cell wall material in the process of the establishment of FE models.

THE STRUCTURE CONTROL OF ALUMINUM FOAMS PRODUCED BY POWDER COMPACTED FOAMING PROCESS

A new technique, powder compact foaming process for the production of aluminumfoams has been studied in this article. According to this method, the aluminum pow-der is mixed with a powder foaming agent (TiH_2). Subsequent to mixing, the powderblend is hot compacted to obtain a dense semi--finished product. Upon heating to tem-peratures within the range of the melting point, the foaming agent decomposes to evolvegas and the semi--finished product expands into a porous cellular aluminum. Foamingprocess is the key in this method. Based on experiments, the foaming characteris-tics were mainly analyzed and discussed. Experiments show that the aluminum--foamwith closed pores and a uniform cell structure of high porosity can be obtained usingthis method by adjusting the foaming parameters: the content of foaming agent andfoaming temperature.

Impact damage behavior of sandwich composite with aluminum foam core

Impact property of the sandwich composite with aluminum foam core was investigated by experiment and simulation analysis. Impact energies of 50, 70 and 100 J were applied to the specimens in impact tests. The results show that the striker penetrates the upper face sheet, causing the core to be damaged at 50 J test but the lower face sheet remains intact with no damage. At 70 J test, the striker penetrates the upper face sheet and the core,and causes the lower face sheet to be damaged. Finally at 100 J test, the striker penetrates both the upper face sheet and the core, and even the lower face sheet. The experimental and simulation results agree with each other. By the confirmation with the experimental results, all these simulation results can be applied on structure study of real sandwich composite with aluminum foam core effectively.

Cell-structure and mechanical properties of closed-cell aluminum foam

The density, cell size and structure of closed-cell aluminum foam were measured by optical microscopy and image analysis. The properties and the mechanism of compressive deformation that occur in closed-cell aluminum foam were measured and discussed. The results show that the cell size of foam with density of 0.37 mg/m^3 is distributed in the range of 0.5 4.0 mm. The cell size of foam with density of 0.33 mg/m^3 is distributed in the range of 0.55.0 mm. The cell wall thickness of both types is 0.10.3 mm. The closed-cell aluminum foam almost belongs to isotropic one, with a variation of ±15% in elastic modulus and yield strength in longitudinal and transverse direction. Under compressive loading, foam materials show inhomogeneous macroscopic deformation. The site of the onset of local plastic deformation depends on the cell structure. The shape of cell is more important than size in determining the yielding susceptibility of the cells. At early stage of deformation,the deformation is localized in narrow bands having width of one cells diameter, and outside the bands the cell still remains the original shape. The cells within bands experience large permanent deformation. The band normals are usually within 20° of the loading axis.

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.

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.

Sound absorption property of open-pore aluminum foams

The sound absorption property of aluminum foam was studied by testing its sound absorption coefficients using standing wave tube method. The open-pore aluminum foams were prepared by infiltration process, with pore size of 0.5 mm to 3.2 mm and porosity of 54.2% to 77%. The frequency of indicted sound wave was ranging from 125 Hz to 10 kHz. The results show that the average values of sound absorption coefficients are all over 0.4 and the aluminum foam has better sound absorption property, its coefficients is influenced by frequency and pore structure, and reaches the maximum at about 1 kHz, with increasing porosity and decreasing cell diameter the sound absorption coefficient values increase.

Compression behavior and constitutive model establishment of fly ash cenosphere/polyurethane aluminum alloy syntactic foam

The aluminum matrix syntactic foam was fabricated by pressure infiltration technique,and the filling material is syntactic foam material with fly ash cenosphere as the main component and polyurethane foam as the binder.Split Hopkinson pressure bar(SHPB)dynamic compression and quasi-static tests were carried out to examine the compressive response of syntactic foam in this study.Then the dynamic constitutive model was established.Results show that the compressive stress-strain curve of syntactic aluminum foam is similar to that of other metallic foam materials:both kinds of aluminum matrix syntactic foams have strain rate effect,and the syntactic foam has higher compressive strength and energy absorption than the same density aluminum foams.However,due to the different sizes of cenospheres,the dynamic compression results of two kinds of syntactic foams are different,and the energy absorption effect of syntactic foam with small size under dynamic impact is the best.In the range of strain rate and density studied experimentally,the curves of constitutive model fit well with the curves of experimental data.

Effect of manganese on the ferrum phases of B319 aluminum alloy in lost foam casting

By using ICP spectroscopy, energy dispersive spectroscopy (EDS) analysis, X-ray diffraction, SEM and microscope analysis, the effects of Mn on the structure of B319 aluminum alloy are studied. The results show that without the addition of Mn, there are coral-like Al_2Cu phase and needle-like β-Fe (Al_5FeSi)in the structure of casting with lost foam casting (LFC). Precipitation of Al_2Cu can take place along the long sides of the β needles. Under the rapid cooling rates, such as ones in metallic mold, the Fe phase appears in the form of Chinese script α-Fe. With the addition of Mn, there are Chinese script α-Fe phases(Al_(15) (Mn, Fe)_3Si_2)in the structure of LFC casting. When Fe/Mn≤1.5, the needle-like β-Fe phases transform to Chinese script α-Fe completely. With the decrease of Fe/Mn ratio, the tensile strength σ_b and elongation δ increase, especially the elongation δ increases greatly. When Fe/Mn ratio decreases from 2.5 to 1, the δ increases from 1.2% to 1.9% by 58%.

Effect of Silicon Carbide and Titanium Hydride on the Foamability of Aluminum Alloy (6061)

Aluminum foam is a light weight material with good mechanical and energy absorption properties. In this study, aluminum foam composite was fabricated using aluminum powder 6061 and silicon carbide (SiC) powder. Titanium hydride (TiH2) was used as the foaming agent. Cold compact followed by hot pressing (sintering) was used to produce the composite precursor. Foaming was carried out, following the sintering process, by heating the aluminum composite precursor to a temperature above the melting point of aluminum (Al). The linear expansion of the foam and the percent porosity were found to increase as the SiC percentage decreased from 10 to 4%, whereas the density got lower. The percent porosity and linear expansion were both found to increase as the percentage of the foaming agent was increased from 0.5 to 1.5%. Compression stress was evaluated for two different porosity values (40% and 47%), and found to be higher for the samples with lower percent porosity at the same strain value. Effect of shape memory alloy fiber, made of nickel and titanium (NiTi), on the mechanical properties was also investigated. The compression stress was higher, in the densification region, for the samples in which NiTi was used.

Corrosion behavior of SiC foam ceramic reinforced Al-23Si composites in NaCl solution

SiC foam ceramic reinforced aluminum matrix composites(SFCAMCs)were prepared by squeeze casting aluminum alloy(Al-23Si)into the SiC foam ceramic with different pore sizes,and the corrosion behavior of the SFCAMCs was studied in NaCl solutions.Static immersion corrosion tests were conducted at 20°C,50°C and 80°C,respectively.Corrosion morphology and products were analyzed by scanning electron microscope,energy dispersive system and X-ray diffraction.It was found that the corrosion rate of SFCAMCs increases as the temperature rising,and the bigger pore size of SiC foam ceramic reinforcement,the better corrosion resistance of SFCAMCs.

EFFECT OF La-RICH RE ON THE STRUCTURE AND PROPERTIES OF B319 ALLOY IN LOST FOAM CASTING

By use of ICP spectroscopy,energy spectrum analysis,hydrogen tester,image analyzer,the differential scanning calorimetric(DSC)and microscope analysis,the effects of RE on the Porosity,structure and properties of B319 aluminum alloy were studied.The results show that under the 0.3°C/s slow cooling rate in lost foam casting,the effect of RE on modification and grain size of B319 aluminum alloy is little.With the increase of RE master alloy,the tensile strength and elongation increase.When RE>0.15%,block like La_(2)Si_(2)Al_(3)phase appear,and the tensile strength and elongation decrease.The results also show that the melt hydrogen content and casting porosity can be decreased greatly by adding 0.15%RE to aluminum melt.This is the important reason why RE improves the mechanical properties of casting under lost foam casting condition.

泡沫铝填充薄壁金属圆管吸能特性的预测及优化方法

为提高泡沫铝填充薄壁金属圆管的吸能特性并进行高效率结构设计,基于均匀拉丁超立方试验设计方法和径向基函数神经网络,构建轴向冲击下泡沫铝填充铝管吸能特性的近似模型,并将近似模型嵌入遗传算法中实现构件的结构优化。研究结果表明:基于径向基函数神经网络构建的近似模型的拟合优度大于0.99、均方根误差小于0.08,且近似模型的计算耗时仅为数值计算的0.56%;近似模型在保证较高精度的同时可大幅提高计算效率;对泡沫铝填充铝管的结构优化发现,通过增大圆管半径和壁厚、减小高度可使泡沫铝填充铝管的平均压缩力最大化,反之,可使泡沫铝填充铝管的峰值压缩力最小化;基于遗传算法的多目标优化显著提高了泡沫铝填充铝管的吸能特性;该研究成果可为泡沫铝填充薄壁金属圆管的快速设计和优化提供参考。

基于光谱学分析的硬质聚氨酯泡沫/钢渣/次磷酸铝复合材料阻燃机理研究

硬质聚氨酯泡沫(RPUF)的优异性能使其在各领域被广泛应用,但本身的易燃性为其在应用过程中埋下了巨大的安全隐患。钢渣(SS)作为提炼铁精矿后排放的固体废弃物,因其综合利用效率低下而造成一系列环境污染问题。为提高RPUF火灾安全性和钢渣的附加值,将SS和次磷酸铝(AHP)引入到RPUF中,采用一步全水发泡法,制备一系列阻燃RPUF(FR-RPUF)复合材料。利用射线荧光光谱分析(XRF)探究了SS的化学成分,并系统研究了SS/AHP对FR-RPUF复合材料的微观形貌、热稳定性、阻燃性能以及气相产物的影响。XRF测试表明:钢渣的化学成分主要是CaO、SiO_(2)、Al_(2)O_(3)、Fe_(2)O_(3)、SO_(3)、MgO,以上金属氧化物能够作为协效剂促进聚合物成炭,并覆盖在材料表面阻隔燃烧热,在凝聚相达到阻燃目的。扫描电镜(SEM)测试表明:SS/AHP与RPUF基体的相容性较差导致FR-RPUF的泡孔出现不同程度的破损。阻燃测试表明:RPUF-1、RPUF-4、RPUF-5的极限氧指数分别为24.2 vol%、23.4 vol%、19.7 vol%,说明SS和AHP存在一定的协效阻燃作用,且RPUF/SS/AHP复合材料全部通过UL-94 V-0级别,满足外墙保温材料使用要求。热重-红外分析(TG-FTIR)测试表明:SS/AHP并未改变RPUF的降解过程,气相产物主要为碳氢化合物、羰基化合物、氨基甲酸酯、CO_(2)、异氰酸酯化合物、芳香族化合物、氰化氢、羰基化合物和酯类。对典型挥发性产物进一步分析发现,AHP和SS的加入促进RPUF基体早期降解。拉曼测试表明:当SS/AHP加入到RPUF后,RPUF-4的D峰与G峰的峰面积比(I_(D)/I_(G))值最小,表明SS/AHP的加入提高了FR-RPUF复合材料炭渣的致密性、石墨化程度。结合上述分析提出阻燃机理:首先AHP吸热分解,降低了火焰周围的温度,其分解的PO·自由基捕获游离的HO·抑制连锁反应,分解产生的焦磷酸铝与炭渣覆盖在基体表面,抑制了火焰和可燃气体的扩散。AHP分解产生的PH3遇氧气生成酸性物质(磷酸和聚磷酸),促进了RPUF脱水成炭,并且钢渣中的矿物成分会与磷酸或聚磷酸反应,形成致密炭层,与AHP共同发挥协效阻燃作用。研究为SS和AHP复配阻燃硬质聚氨酯泡沫材料提供理论依据和实验基础。

基于熔体发泡法泡沫铝填充管力学性能研究

采用熔体发泡法制备闭孔泡沫铝,研究泡沫铝填充密度对铝合金薄壁管的压缩及吸能性能提升作用,对比提升效果,确定最佳密度参数;并在最佳密度的基础上设计三类不同截面的复合结构,研究填充管的截面结构对压缩性能及吸能性能的影响,确定最佳结构参数。采用万能试验机进行准静态压缩试验,并利用有限元模拟结果与试验结果相对比,验证数据准确性。结果表明:填充梯度泡沫铝会增加薄壁管的力学性能,如屈服强度、平均压溃载荷和吸能性能,降低曲线波动性,密度为0.480 5 g/cm3的闭孔泡沫铝表现出最优结果;二次试验中,复合结构能进一步提升薄壁管的力学性能,其中外方管内圆管的复合结构具有最高的屈服强度、平均压溃载荷以及吸能效果。

压制工艺对粉末冶金法制备泡沫铝孔结构的影响

以AlSi粉末为基体,TiH2作为发泡剂,通过研究冷压和热压两种粉末冶金工艺制备泡沫铝,分析冷压压力和热压温度对前驱体相对密度和泡沫铝孔结构的影响。实验表明,提高冷压压力和热压温度均可增加前驱体相对密度,当冷压压力超过400 MPa后对泡沫铝孔结构、膨胀率和孔隙率没有明显改善的趋势。增加热压温度可促进Al-Si共晶相生成并稳定泡沫结构。在450℃热压温度下,可制得孔结构良好、孔隙率为81.7%泡沫铝。

高温环境下多壁管增强泡沫铝压溃行为的理论分析与数值模拟研究

通过理论和数值模拟方法研究了新型高效吸能结构——多壁管增强泡沫铝在高温环境下的压溃特性及能量吸收性能。采用能量法预测了多壁管增强泡沫铝的轴向压缩平均力,在此基础上研究了温度以及泡沫铝与多壁管材料流动应力之比对结构吸能效率的影响。结果表明:理论预测值与有限元结果吻合较好,最大误差值为-6.7%;环境温度从室温上升至350℃,温度升高导致材料力学性能下降,多壁管增强泡沫铝平均力下降了1/3;另外,流动应力之比会影响多壁管半折叠波长或塑性铰数目,因此通过控制合适的流动应力之比可以提高结构吸能效率。

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。

泡沫铝复合结构隔声性能的仿真和实验研究

泡沫铝材料在交通运输、航天和建筑隔声等方面具有广阔的应用前景,然而单层泡沫铝其内部孔径和孔隙率不同严重影响了材料的隔声效果。构造两种复合结构,分别采用COMSOL软件仿真和实验室阻抗管测试两种手段对隔声性能进行了研究,结果表明:泡沫铝-玻璃纤维吸音棉复合结构在低频和中高频的隔声性能有一定的改进,而对于泡沫铝-三聚氰胺海绵复合结构,其隔声性能在各个频段均得到了极大提升,平均隔声量提升了将近6.8dB。