Metal Foams: A Design Guide

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224 Metal Foams: A Design Guide illustrates a DUOCEL foamed aluminum composite sunshade for an optical telescope satellite. 17.5 Fluid–fluid heat exchangers Figure 17.8 illustrates the structure of a fluid–fluid heat exchanger constructed from ERG DUOCEL ® open-celled aluminum foam. Ł Heat exchange criteria are analysed in Chapter 13 of this Design Guide. Open porosity, low relative Figure 17.8 DUOCEL ® foamed aluminum used as the heat-exchange medium for the space shuttle atmospheric control system. (Courtesy of ERG) Ł Contact details: ERG Materials and Aerospace Corporation, 900 Stanford Ave, Oakland, CA 94608, USA. Phone: (510) 658-9785; Fax: (510) 658-7428.
Case studies 225 density and high thermal conductivity of the cell edges are essential. The DUOCEL range of metal foams, which include both aluminum and copper, offer this combination of properties. The figure shows a foamed aluminum heat exchanger for a space-shuttle atmospheric control system. 17.6 Light weight conformal pressure tanks Fluids in pressure tanks, ranging from aircraft fuel to liquid nitrogen cryogen for airborne infrared telescopes, must be maintained at constant and uniform temperature, uniform pressure, and – in moving systems – must be restrained from ‘sloshing’ because this generates pressure gradients. Figure 17.9 shows the design of a tank which exploits ERG DUOCEL ® open-celled aluminum foam to achieve this. The foam has a low density, occupying only 10% of the volume of the tank, but it limits fluid motion. The high thermal conductivity of the cell edges maintains the fluid at a constant temperature, important for jet fuel. Ł Figure 17.9 DUOCEL ® foamed aluminum used as the structural core, heat exchanger and anti-slosh baffle in a lightweight conformal tank. (Courtesy of ERG) 17.7 Electrodes for batteries Nickel rechargeable batteries systems, nickel cadmium (NiCd) and nickel metal hydride (NiMH) are the most widely used batteries for consumer Ł Contact details: ERG Materials and Aerospace Corporation, 900 Stanford Ave, Oakland, CA 94608, USA. Phone: (510) 658-9785; Fax:(510) 658-7428.
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Metal Foams: A Design Guide
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Copyright © 2000 by Butterworth-He
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vi Contents 4.3 Foam property chart
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viii Contents 17 Case studies 217 1
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List of contributors M.F. Ashby Cam
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Table of physical constants and con
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Chapter 1 Introduction Metal foams
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Activity Research Industrial take-u
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Application Comment Introduction Bi
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Cell size (cm) Making metal foams 7
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Making metal foams solidify. The th
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Making metal foams 11 2.4 Gas-relea
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a) Preform Polymer ligaments d) Rem
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a) Vapor deposition of Nickel b) Bu
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Process Steps a) Powder / Can prepa
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Making metal foams 19 flight in a t
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a) Metal - Hydrogen binary phase di
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Entrapped gas expansion Making meta
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(a) (b) (c) 100µm Characterization
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E/E bulk σ peak /σ bulk 1.2 1.0 0
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Stress (MPa) Characterization metho
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Characterization methods 31 foam sp
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Characterization methods 33 ž Prop
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F/2 F/2 F/2 F/2 τ Core Characteriz
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Characterization methods 37 40 40 4
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Characterization methods 39 Gioux,
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(a) (b) (c) Properties of metal foa
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Table 4.1 (a) Ranges a for mechanic
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Stress, σ Schematic Young's modulu
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Properties of metal foams 47 foams.
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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
Page 185 and 186: Sound absorption and vibration supp
Page 189 and 190: 0 Sound absorption and vibration su
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Page 195 and 196: Thermal management and heat transfe
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Page 199 and 200: ~ P ~ Re 2.6 1000 800 600 400 200 0
Page 201 and 202: Chapter 14 Electrical properties of
Page 203 and 204: Electrical properties of metal foam
Page 205 and 206: Electrical properties of metal foam
Page 207 and 208: 15.3 Joining of metal foams Cutting
Page 209 and 210: Pull-out load, F p (N) 10 5 10 4 10
Page 211 and 212: Cyclic loading of fasteners Cutting
Page 213 and 214: Time, material, energy, capital, in
Page 215 and 216: Cost estimation and viability 203 A
Page 217 and 218: $/Unit Melting Schematic of the liq
Page 219 and 220: Performance metric, P2 B Non-domina
Page 221 and 222: Cost estimation and viability 209 t
Page 223 and 224: Cost estimation and viability 211 i
Page 225 and 226: P 2 = 1/Loss coefficient (−) 1000
Page 227 and 228: Cost estimation and viability 215 C
Page 229 and 230: Chapter 17 Case studies Metal foams
Page 231 and 232: Case studies 219 Figure 17.2 A pres
Page 233 and 234: Case studies 221 Figure 17.4 Highwa
Page 235: Case studies 223 Figure 17.6 DUOCEL
Page 239 and 240: Case studies 227 required for compa
Page 241 and 242: Maximum power density at electronic
Page 243 and 244: q *(MW/m 2) 15 10 Power density fix
Page 245 and 246: Case studies 233 which optimized sk
Page 247 and 248: e-mail: cymat@ican.net Web: www.cym
Page 249 and 250: Tel: C0043 7722 801-2125 Fax: C0043
Page 251 and 252: Chapter 19 Web sites An increasing
Page 253 and 254: http://www.seac.nl/english/recemat/
Page 255 and 256: (b) (continued) Appendix: Catalogue
Page 257 and 258: (f) Vibration-limited design Append
Page 259 and 260: Index (Company and trade names are
Page 261 and 262: Heat transfer 4, 182 Heat transfer
Page 263: Surface strain mapping 36 Syntactic
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Metal Foams: A Design Guide

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