Metal Foams: A Design Guide

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236 Metal Foams: A Design Guide Newark, DE 19716 USA Tel: C1 302 369 6752 Fax: C1 302 369 6763 e-mail: yu@frc-de.fraunhofer.com Fraunhofer-Dresden (Dr D.O. Anderson) Fraunhofer-IFAM Dresden Winterbergstraßae 28 D-01277 Dresden Germany Tel: C49 351 2537 319 Fax: C49 351 2537 399 e-mail: Anderson@epw.ifam.fhg.de *SCHUNK (Dipl.-Ing. F. Baumgärtner) Schunk Sintermetalltechnik GmbH Postfach 10 09 51 D-35339 Gießen Germany Tel: C49 641 608 1420 Fax: C049 641 608 1734 e-mail: frank.baugaertner@schunk-group.com *MEPURA (Professor P. Degischer, Director) Mepura Metallpulvergesellschaft m.b.H. Ranshofen A-4813 Altmunster Grossalmstrasse, 5, Austria Tel: C0043 7612 88055-0 Fax: C0043 7612 88055-29 and Metallpulvergesellschaft m.b.H. Ranshofen A-5282 Braunau-Ranshofen Austria Tel: C0043 7722 2216 Fax: C0043 7722 68154 *LKR (Professor P. Degischer, Director Leichtmetall Kompetenzzentrum Ranshofen PO Box 26 A 5282 Ranshofen Austria
Tel: C0043 7722 801-2125 Fax: C0043 7722 64393 e-mail: silberhumer@zdvaxf.arcs.ac.at MEPURA-SLOVAKIA (Dr F. Simancik, Director) Slovak Academy of Sciences Department of Powder Metallurgy PO Box 95 Racianska 75 Slovakia Tel: (C42) 7 253000 Fax: (C42) 7 253301 *NEUMAN ALU FOAM Neuman Alu Foam A-3182 Marktl Austria Tel: (C43) 2762 500 670 Fax: (C43) 2762 500 679 e-mail: hoepler@neuman.at GASAR DML Dnepropetrovsk Mettalurgical Institute Ukraine *HYDRO (Dr P. Asholt) Hydro Aluminum, a.s. R&D Materials Technology PO Box 219 N 6601 Sunndals ra Norway Tel: C0047 71 69 3000 Fax: C0047 71 69 3602 HOLLOW-SPHERE FOAM (Professor Joe Cochran) Georgia Institute of Technology Materials Science and Engineering 778 Atlantic Drive Atlanta, GA 30332 USA Tel: C001 404-894-6104 Fax: C001 404-894-9140 e-mail: joe.Cochran@mse.gatech.edu JAM Corp. (Jon Priluc, President) JAM Corp. Suppliers of metal foams 237
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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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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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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 and 238: Case studies 225 density and high t
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: e-mail: cymat@ican.net Web: www.cym
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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