Metal Foams: A Design Guide

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xiv Conversion units Conversion of units Stress intensity, KIC 1 ksi p in 1.10 MN/m 3/2 Surface energy, 1 erg/cm 2 1mJ/m 2 Temperature, T 1°F 0.556°K Thermal conductivity, 1 cal/s.cm.°C 418.8 W/m.°C 1 Btu/h.ft.°F 1.731 W/m.°C Volume, V 1 Imperial gall 4.546 ð 10 3 m 3 1 US gall 3.785 ð 10 3 m 3 Viscosity, 1 poise 0.1 N.s/m 2 1 lb ft.s 0.1517 N.s/m 2 Conversion of units – stress and pressure Ł MN/m 2 dyn/cm 2 lb/in 2 kgf/mm 2 bar long ton/in 2 MN/m 2 1 10 7 1.45 ð 10 2 0.102 10 6.48 ð 10 2 dyn/cm 2 10 7 1 1.45 ð 10 5 1.02 ð 10 8 10 6 6.48 ð 10 9 lb/in 2 6.89 ð 10 3 6.89 ð 10 4 1 703 ð 10 4 6.89 ð 10 2 4.46 ð 10 4 kgf/mm 2 9.81 9.81 ð 10 7 1.42 ð 10 3 1 98.1 63.5 ð 10 2 bar 0.10 10 6 14.48 1.02 ð 10 2 1 6.48 ð 10 3 long ton/in 2 15.44 1.54 ð 10 8 2.24 ð 10 3 1.54 1.54 ð 10 2 1 Conversion of units – energy Ł J erg cal eV Btu ft lbf J 1 10 7 0.239 6.24 ð 10 18 9.48 ð 10 4 0.738 erg 10 7 1 2.39 ð 10 8 6.24 ð 10 11 9.48 ð 10 11 7.38 ð 10 8 cal 4.19 4.19 ð 10 7 1 2.61 ð 10 19 3.97 ð 10 3 3.09 eV 1.60 ð 10 19 1.60 ð 10 12 3.38 ð 10 20 1 1.52 ð 10 22 1.18 ð 10 19 Btu 1.06 ð 10 3 1.06 ð 10 10 2.52 ð 10 2 6.59 ð 10 21 1 7.78 ð 10 2 ft lbf 1.36 1.36 ð 10 7 0.324 8.46 ð 10 18 1.29 ð 10 3 1 Conversion of units – power Ł kW (kJ/s) erg/s hp ft lbf/s kW (kJ/s) 1 10 10 1.34 7.38 ð 10 2 erg/s 10 10 1 1.34 ð 10 10 7.38 ð 10 8 hp 7.46 ð 10 1 7.46 ð 10 9 1 5.50 ð 10 2 ft lbf/s 1.36 ð 10 3 1.36 ð 10 7 1.82 ð 10 3 1 Ł To convert row unit to column unit, multiply by the number at the column–row intersection, thus 1MN/m 2 D 10 bar
Chapter 1 Introduction Metal foams are a new, as yet imperfectly characterized, class of materials with low densities and novel physical, mechanical, thermal, electrical and acoustic properties. They offer potential for lightweight structures, for energy absorption, and for thermal management; and some of them, at least, are cheap. The current understanding of their production, properties and uses in assembled in this Design Guide. The presentation is deliberately kept as simple as possible. Section 1.1 expands on the philosophy behind the Guide. Section 1.2 lists potential applications for metal foams. Section 1.3 gives a short bibliography of general information sources; further relevant literature is given in the last section of each chapter. At this point in time most commercially available metal foams are based on aluminum or nickel. Methods exist for foaming magnesium, lead, zinc, copper, bronze, titanium, steel and even gold, available on custom order. Given the intensity of research and process development, it is anticipated that the range of available foams will expand quickly over the next five years. 1.1 This Design Guide Metallic foams (‘metfoams’) are a new class of material, unfamiliar to most engineers. They are made by a range of novel processing techniques, many still under development, which are documented in Chapter 2. At present metfoams are incompletely characterized, and the processes used to make them are imperfectly controled, resulting in some variability in properties. But even the present generation of metfoams have property profiles with alluring potential, and the control of processing is improving rapidly. Metfoams offer significant performance gains in light, stiff structures, for the efficient absorption of energy, for thermal management and perhaps for acoustic control and other, more specialized, applications (Section 1.2). They are recyclable and nontoxic. They hold particular promise for market penetration in applications in which several of these features are exploited simultaneously. But promise, in today’s competitive environment, is not enough. A survey of the history of development of new material suggests a scenario like that sketched in Figure 1.1. Once conceived, research on the new material accelerates rapidly, driven by scientific curiosity and by the often over-optimistic
Page 1 and 2: Metal Foams: A Design Guide
Page 3 and 4: Copyright © 2000 by Butterworth-He
Page 5 and 6: vi Contents 4.3 Foam property chart
Page 7 and 8: viii Contents 17 Case studies 217 1
Page 9 and 10: List of contributors M.F. Ashby Cam
Page 11: Table of physical constants and con
Page 15 and 16: Activity Research Industrial take-u
Page 17 and 18: Application Comment Introduction Bi
Page 19 and 20: Cell size (cm) Making metal foams 7
Page 21 and 22: Making metal foams solidify. The th
Page 23 and 24: Making metal foams 11 2.4 Gas-relea
Page 25 and 26: a) Preform Polymer ligaments d) Rem
Page 27 and 28: a) Vapor deposition of Nickel b) Bu
Page 29 and 30: Process Steps a) Powder / Can prepa
Page 31 and 32: Making metal foams 19 flight in a t
Page 33 and 34: a) Metal - Hydrogen binary phase di
Page 35 and 36: Entrapped gas expansion Making meta
Page 37 and 38: (a) (b) (c) 100µm Characterization
Page 39 and 40: E/E bulk σ peak /σ bulk 1.2 1.0 0
Page 41 and 42: Stress (MPa) Characterization metho
Page 43 and 44: Characterization methods 31 foam sp
Page 45 and 46: Characterization methods 33 ž Prop
Page 47 and 48: F/2 F/2 F/2 F/2 τ Core Characteriz
Page 49 and 50: Characterization methods 37 40 40 4
Page 51 and 52: Characterization methods 39 Gioux,
Page 53 and 54: (a) (b) (c) Properties of metal foa
Page 55 and 56: Table 4.1 (a) Ranges a for mechanic
Page 57 and 58: Stress, σ Schematic Young's modulu
Page 59 and 60: Properties of metal foams 47 foams.
Page 61 and 62: Properties of metal foams 49 show t
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Modulus 0.5 /Density (GPa 0.5 /(Mg/
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elations take the form P Ł � Ł
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Chapter 5 Design analysis for mater
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Table 5.1 Design requirements Desig
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Design analysis for material select
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5.4 Where might metal foams excel?
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Table 6.1 Constitutive equations fo
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h SECTION h o h i d d o a b ;;; QQQ
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6.3 Elastic deflection of beams and
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6.4 Failure of beams and panels (a)
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;; ;;; ;; M ;; ;;; ;; ;;; ;; ;; ;;
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Torsion of shafts T T,q T T,q Yield
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R a 2 Flow field R F R 2a 2 F F s c
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;; ; QQ Q ¢¢ ¢ ;; ;; QQ QQ ¢¢
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; ;; Creep p e p e • Area A u F 2
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and its deviatoric (i.e. shear) com
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Normalized effective stress 1.4 1.2
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A constitutive model for metal foam
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A constitutive model for metal foam
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Stress amplitude, ∆σ + Stress,
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Axial strain (%) 5 4 3 2 1 0 0 σma
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Nominal compressive strain Nominal
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σ max σ pl τ max τ pl σ max σ
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Design for fatigue with metal foams
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the net section stress criterion re
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E σ pl (m) 10 1 0.1 0.01 0.1 Relat
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Chapter 9 Design for creep with met
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Design for creep with metal foams 1
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instead to: � Pε 3 D Pε0 2 s Ł
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Time to failure (hours) 10 2 10 1 1
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Design for creep with metal foams 1
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Chapter 10 Sandwich structures Sand
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Sandwich structures 115 The elastic
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Indentation Sandwich structures 117
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H H Core shear Core shear Collapse
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0.5 10−1 t c t c 10 −2 0.5 10
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Sandwich structures 123 the contact
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Sandwich structures 125 four sectio
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c t p p Figure 10.9 Sandwich panel
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Sandwich structures 129 with k ¾ D
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c/ Face sheet yielding 0.14 0.12 0.
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Weight index, ψ 10 −1 10 −2 10
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Sandwich structures 135 To construc
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Sandwich structures 137 The associa
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Sandwich structures 139 Note that,
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where D � 2⊲1 Eft 2 f ⊳GcR Sa
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Weight index ψ = W/2πR 2 ρ s W c
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Sandwich structures 145 plastic yie
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Sandwich structures 147 within the
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Sandwich structures 149 Shuaeib, F.
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Energy management: packaging and bl
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Energy/Unit cost (kJ/£) 10 1 0.1 0
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ys crushes axially at the load Ener
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peak pressure MPa Impulse/(mass of
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Chapter 12 Sound absorption and vib
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Sound absorption and vibration supp
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0 Sound absorption and vibration su
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Chapter 13 Thermal management and h
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Thermal management and heat transfe
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Thermal management and heat transfe
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~ P ~ Re 2.6 1000 800 600 400 200 0
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Chapter 14 Electrical properties of
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Electrical properties of metal foam
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Electrical properties of metal foam
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15.3 Joining of metal foams Cutting
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Pull-out load, F p (N) 10 5 10 4 10
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Cyclic loading of fasteners Cutting
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Time, material, energy, capital, in
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Cost estimation and viability 203 A
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$/Unit Melting Schematic of the liq
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Performance metric, P2 B Non-domina
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Cost estimation and viability 209 t
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Cost estimation and viability 211 i
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P 2 = 1/Loss coefficient (−) 1000
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Cost estimation and viability 215 C
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Chapter 17 Case studies Metal foams
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Case studies 219 Figure 17.2 A pres
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Case studies 221 Figure 17.4 Highwa
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Case studies 223 Figure 17.6 DUOCEL
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Case studies 225 density and high t
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Case studies 227 required for compa
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Maximum power density at electronic
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q *(MW/m 2) 15 10 Power density fix
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Case studies 233 which optimized sk
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e-mail: cymat@ican.net Web: www.cym
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Tel: C0043 7722 801-2125 Fax: C0043
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Chapter 19 Web sites An increasing
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http://www.seac.nl/english/recemat/
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(b) (continued) Appendix: Catalogue
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(f) Vibration-limited design Append
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Index (Company and trade names are
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Heat transfer 4, 182 Heat transfer
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Surface strain mapping 36 Syntactic
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Metal Foams: A Design Guide

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