Metal Foams: A Design Guide

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226 Metal Foams: A Design Guide portable applications such as power tools, video cameras and cellular phones. Ł Different nickel battery designs are required to meet these various applications. Properties can be varied to meet the needs of power, cycle life and energy density. When energy density is the most important characteristic, nickel batteries have made gains by using nickel foam as the electrodes, and the development of the nickel metal hydride system with a hydrogen-absorbing nickel alloy as the negative electrode. Nickel foams can be made to different densities, thicknesses and porosity to optimize performance using the process described in Chapter 2, Section 2.6. These nickel battery systems are now being specified by the world’s leading automotive companies (GM, Toyota, Honda) for the next generation of electric and hybrid vehicles. Nickel foams can also be used as filtration media. Figure 17.10 A nickel foam positive electrode as used in NiCd and NiMeH batteries. (Courtesy of Inco Ltd.) 17.8 Integrated gate bipolar transistors (IGBTs) for motor drives Present motor drives generally comprise integrated gate bipolar transistors (IGBTs) because they are capable of operating at the high power densities Ł Contact details: Inco Ltd, 145 King Street West, Suite 1500, Toronto, Canada, M5H 4B7. Phone: (416) 361-7537; Fax: (416) 361-7659. Inco European Ltd, London office, 5th floor, Windsor House, 50 Victoria Street, London SW1H OXB. Phone (44) 171 932-1516; fax (44) 171 9310175.
Case studies 227 required for compactness. Each IGBT in commercial systems is configured as shown in Figure 17.11. Each module comprises several IGBTs with an equal number of diodes (six would be typical for a 75 hp motor drive). In steady operation, the heat, q, generated at the electronics in each IGBT may be as large as 6 MW/m 2 . The flux is in one direction and is transferred to the coolant by a heat sink comprising a fin-pin array subject to flowing air generated by a fan. Conventional air-cooled heat sinks operate at fluxes, q � 2kW/m 2 (Figure 17.12). The ratio q/q is accommodated by designing the sink with a cross-sectional dimension, bhs, that relates to that for the Si, bsi, Plastic housing Gel Wirebonded encapsule interconnections Silicon Soldered interconnections Ceramic insulation 2b hs = 50 cm Power terminals Figure 17.11 Conventional power electronic packaging Temperature Difference (°C) 10 3 10 2 10 10 −4 1 Direct Air, natural convection + radiation Direct air, forced convection 10 −3 Immersion-Boiling fluorocarbons Immersion, natural convection fluorocarbons Water, forced convection 10 −2 Surface heat flux (MW/m 2 ) 10 −1 Figure 17.12 Performance domains for heat sinks Aircooled mesocell heat sink Metal baseplate
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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
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Sound absorption and vibration supp
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Page 191 and 192: Sound absorption and vibration supp
Page 193 and 194: Chapter 13 Thermal management and h
Page 195 and 196: Thermal management and heat transfe
Page 197 and 198: Thermal management and heat transfe
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 and 236: Case studies 223 Figure 17.6 DUOCEL
Page 237: Case studies 225 density and high t
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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