Metal Foams: A Design Guide

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12 Metal Foams: A Design Guide a) Select Ingredients ...and mix Metal alloy powder PARTICLE DECOMPOSITION IN SEMI-SOLID Powder Steel ball bearings Rotating impeller b) Consolidation & Extrusion Ram Preconsolidated billet c) Shaped mold Extrusion die Foaming agent Dense bar or plate Shaped container Extruded alloy bar or plate (containing foaming agent) d) Foaming Foamed component Shaped mold Furnace Figure 2.4 The sequence of powder metallurgy steps used to manufacture metal foams by gas-releasing particles in semi-solids (the Fraunhofer and the Alulight processes)
a) Preform Polymer ligaments d) Remove mold material c) Infiltrate SOLIDIFICATION IN OPEN CELL MOLD b) Burnout Casting slurry (sand) H 2O CO Open channels Mold material Pressure Molten metal Making metal foams 13 Metal ligaments Figure 2.5 Investment casting method used to manufacture open cell foams (DUOCEL process) An open-cell polymer foam mold template with the desired cell size and relative density is first selected. This can be coated with a mold casting (ceramic powder) slurry which is then dried and embedded in casting sand. The mold is then baked both to harden the casting material and to decompose (and evaporate) the polymer template, leaving behind a negative image of the foam. This mold is subsequently filled with a metal alloy and allowed to cool. The use of a moderate pressure during melt infiltration can overcome the resistance to flow of some liquid alloys. After directional solidification and
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 and 12: Table of physical constants and con
Page 13 and 14: Chapter 1 Introduction Metal foams
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: Making metal foams 11 2.4 Gas-relea
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
Page 63 and 64: Modulus 0.5 /Density (GPa 0.5 /(Mg/
Page 65 and 66: elations take the form P Ł � Ł
Page 67 and 68: Chapter 5 Design analysis for mater
Page 69 and 70: Table 5.1 Design requirements Desig
Page 71 and 72: Design analysis for material select
Page 73 and 74: 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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Page 167 and 168:
Energy/Unit cost (kJ/£) 10 1 0.1 0
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ys crushes axially at the load Ener
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Page 177 and 178:
Page 179 and 180:
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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Page 193 and 194:
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
Page 263:
Surface strain mapping 36 Syntactic
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Metal Foams: A Design Guide

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