Elasto-plastic analysis of crack in metallic foams

To determine the solutions of the well-known problem of a finite width strip with single edge crack,some results on elasto-plastic fracture analysis for metallic foams are reported.Meanwhile,in order to discuss and put an insight into the nonlinear fracture analysis,the Dugdale model for plastic deformation of this configuration for metallic foams is recommended and solved.Combining the asymptotic solution with the Dugdale model and elastic solution,the stress field in the plastic zone and the size of the plastic zone are expressed as analytical forms.Based on Williams expansion method,the estimate of the scale factor is also completed and analyzed.In view of these analytical solutions,the results show the scale factor is a useful parameter for the fracture theory of metallic foams.

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.

Customisable sound absorption properties of functionally graded metallic foams

In this study,functionally graded foam made of Inconel 625 superalloy was successfully produced using the template replication method,with open-cell polyurethane foams as a precursor.The products have a similar pore morphology as the templates and adjacent layers were successfully sintered together by particle bonding.Sound absorption experiments on graded metallic foams reveal that the sound absorption at particular frequency ranges can be improved by various permutations of foam layers.For graded foam of two distinct pore sizes,a mathematical equation was proposed to predict the location of the intersection point of the sound absorption curves,thereby aiding in graded foam design.An increase in sound absorption coefficients by resonance-like effects can be introduced before the intersection points by placing the foam layer of smaller pore size nearer to the sound source.The sound absorption performances can be further customized when the thickness proportion of the pore sizes is changed and when the number of distinct pore sizes used is increased.The sound absorption performance at lower frequencies is generally boosted by resonance-like effects when the layer of foam with the largest pore size is placed furthest from the sound source.Given the same composition of foam with a fixed thickness proportion of pore sizes,one can introduce resonance-like effects to improve the sound absorption performance compared to other permutations while possibly satisfying weight requirements in practical applications.This study provides valuable insights and mathematical guidelines in the design and manufacturing of functionally graded metallic foam for specific applications.

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.

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.

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.

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.

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.

The effects of relative density of metal foams on the stresses and deformation of beam under bending

The exact analytic solution of the pure bending beam of metallic foams is given. The effects of relative density of the material on stresses and deformation are revealed with the Triantafillou and Gibson constitutive law （TG model） taken as the analysis basis. Several examples for individual foams are discussed, showing the importance of compressibility of the cellular materials. One of the objects of this study is to generalize Hill＇s solution for incompressible plasticity to the case of compressible plasticity, and a kinematics parameter is brought into the analysis so that the velocity field can be determined.

Exact Solution of a Cylinder Tube Made of Metallic Foam Under Inner Pressure

Exact solution of the stress and velocity fields of a cylinder tube of metallic foams under inner pressure is given in which the Triantafillou and Gibson constitutive law （TG model） for the material is taken as a basis of the calculation. The nonlinear equation is turned linear equation by introducing a kinematics parameter. The differences between the full condensed materials and the effect of the relative density are also discussed.

Fabrication of Near Net Shape Metallic Foam via Plaster Mould

Fabrication characteristics are unstable in direct foaming method. Therefore, most of near net-shape metallic foams are produced, and investigated by powder metallurgy. Direct foaming method, however, has many benefits （i.e. reduce the unit cost of goods and fabrication process etc.） to fabrication of metallic foams. In this article, the fabrication characteristic of near net-shape metallic foams by direct foaming method was evaluated. Al and Plaster was used for base material and mould material respectively. Ca and TiH2 were added to molten Al as thickening and blowing agent for stable condition of bubbles. Thickening time was about 10 min with a stirring speed of 600 r/min. Foaming time was 30-120 s for evaluation of the optimum foaming condition. Amount of agent was selected by pre-experimental data. Porosity of near net-shape goods was measured by Archimedes method. On the other hand, it seems that increasing poring time and thickening agent make the poor porosity

Experimental Study on Heat Storage Properties Comparison of Paraffin/Metal Foams Phase Change Material Composites

Heat storage properties of phase change materials(PCMs) are essential characteristics that perform a key role in thermal heat energy storage systems.The thermal properties of PCMs can be improved by developing metal foam/PCM composites.The addition of metal foam in PCMs has a significant effect on the thermal characteristics of PCMs.In this paper,the heat storage properties of two different metal foam/PCM composites were experimentally examined.The behavior of paraffin in metal foam(copper and iron-nickel)/paraffin composites concerning pure paraffin at a constant heat flux of 1000 W/m^(2) in three directions simultaneously(x,y,and z) was studied.Paraffin was infiltrated into copper and iron-nickel foams to develop composite materials which resulted in enhancing the thermal conductivity of the paraffin.A comparative analysis is made on the heat storage properties of paraffin in copper and iron-nickel foams/paraffin composites.Inner temperature distribution during the phase transition process is experimentally evaluated.This comparison indicates that temperature uniformity in copper foam/paraffin composite is better than in iron-nickel foam/paraffin composite and pure paraffin at the same heat flux.Experimental results show that at heat flux of 1000 W/m^(2),the heat storage time for copper foam/paraffin composite is 20.63% of that of iron-nickel foam/paraffin composite.

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.

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.

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.

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.

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.

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.

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.

Design and preparation of Zn-based materials possessing both high damping and good mechanical properties

A new idea of design and manufacture of metal based materials possessing both high damping and good mechanical properties was proposed. The key of the idea is the combination of fining restriction damping structures, using all mechanisms and taking advantages of different materials. Based upon this idea a foam ZA27 was prepared by the technology of prefabricated salt mass centrifugal seeping foundry, its tensile strength and compressive strength are 83～119?MPa and 100～189?MPa, respectively. The damping properties of the foam ZA27 increase remarkably after the carpenter pastern or rosin (the damping increased materials) was immerged into it, which approaches to the level of viscous elastic polymer materials ( Q -1 ≥20×10 -3 ). [