Metal Foams: A Design Guide

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22 Metal Foams: A Design Guide Melt gas injection Jin et al. (1990) Method of producing lightweight foamed metal. US Patent No. 4,973,358. Jin et al. (1992) Stabilized metal foam body. US Patent No. 5, 112, 697. Jin et al. (1993) Lightweight metal with isolated pores and its production. US Patent No. 5,221,324. Kenny et al. (1994) Process for shape casting of particle stabilized metal foam. US Patent No. 5,281,251. Niebyski et al. (1974) Preparation of metal foams with viscosity increasing gases. US Patent No. 3,816,952. Sang et al. (1994) Process for producing shaped slabs of particle stabilized foamed metal. US Patent No. 5,334,236. Thomas et al. (1997) Particle-stablilized metal foam and its production. US Patent No. 5,622,542. Particle decomposition in melts Akiyama et al. (1987) Foamed metal and method of producing same. US Patent No. 4,713,277. Elliot, J.C. (1956) Method of producing metal foam. US Patent No. 2,751,289. Gergely, V. and Clyne, T.W. (1998) The effect of oxide layers on gas-generating hydride particles during production of aluminum foams. In Shwartz, D.S., Shih, D.S., Evans, A.G. and Wadley, H.N.G. (eds) Porous and Cellular Materials for Structural Application, Materials Research Society Proceedings, Vol. 521, MRS, Warrendale, PA, USA. Miyoshi, T., Itoh, M., Akiyama, S. and Kitahara, A. (1998) Aluminum foam, ALPORAS, the production process, properties and applications, Shinko Wire Company, Ltd, New Tech Prod. Div., Amagasaki, Japan. Speed, S.F. (1976) Foaming of metal by the catalyzed and controled decomposition of zirconium hydride and titanium hydride. US Patent No. 3,981,720. Particle decomposition in semisolids Baumeister, J. (1988) Methods for manufacturing foamable metal bodies. US Patent 5,151,246. Falahati, A. (1997) Machbarkeitsstudie zur Herstellung von Eisenbasisschaum, Master’s thesis, Technical University, Vienna. Yu, C.-J. and Eifert, H. (1998) Metal foams. Advanced Materials & Processes November, 45–47. MEPURA. (1995) Alulight. Metallpulver GmbH. Brannau-Ranshofen, Austria. Solidification in open-cell molds ERG (1998) Duocel aluminum foam. ERG Corporate Literature and Reports, 29 September. ERG (1998) Duocel physical properties. ERG Corporate Literature and Reports, 29 September. H2/metal eutectic solidification Sharpalov, Yu (1993) Method for manufacturing porous articles. US Patent No. 5,181,549. Sharpalov. (1994) Porous metals. MRS Bulletin, April: 24–28. Zheng, Y., Sridhar, S. and Russell, K.C. (1996) Controled porosity alloys through solidification processing: a modeling study. Mat. Res. Soc. Symp. Proc. 371: 365–398. Vapor (electro) deposition on cellular preforms Babjak et al. (1990) Method of forming nickel foam. US Patent No. 4,957,543.
Entrapped gas expansion Making metal foams 23 Elzey, D.M. and Wadley, H.N.G. (1998) The influence of internal pore pressure during roll forming of structurally porous metals. In Porous and Cellular Materials for Structural Applications, MRS, Warrendale, PA, USA. Kearns, M.W., Blekinsop, P.A., Barber, A.C. and Farthing, T.W. (1988) Manufacture of a novel porous metal. The International Journal of Powder Metallurgy 24: 59–64. Kearns, M.W., Blekinsop, P.A., Barber, A.C. and Farthing, T.W. (1988) Novel porous titanium. Paper presented at Sixth World Conference on Titanium, Cannes, France. Martin, R.L. and Lederich, R.J. (1991) Porous core/BE TI 6-4 development for aerospace structures. In Advances in Powder Metallurgy: Proceeding of the 1991 Powder Metallurgy Conference and Exposition, Powder Metallurgy Industries Federation, Princeton, NJ, USA. Schwartz, D.S. and Shih, D.S. (1998) Titanium foams made by gas entrappment. In Shwartz, D.S., Shih, D.S., Evans, A.G. and Wadley, H.N.G. (eds) Porous and Cellular Materials for Structural Application, Materials Research Society Proceedings, Vol. 521, MRS, Warrendale PA, USA. Hollow sphere consolidation Drury, W.J., Rickles, S.A. Sanders, T.H. and Cochran, J.K. (1989) Deformation energy absorption characteristics of a metal/ceramic cellular solid. In Proceedings of TMS Conference on Light Weight Alloys for Aerospace Applications, TMS-AIME, Warrendale, PA, USA. Kendall, J.M., Lee, M.C. and Wang, T.A. (1982) Metal shell technology based upon hollow jet instability. Journal of Vacuum Science Technology 20, 1091–1093. Lee et al. (1991) Method and apparatus for producing microshells. US Patent No. 5,055,240. Sypeck, D.S., Parrish, P.A. and Wadley, H.N.G. (1998) Novel hollow powder porous structures. In Porous and Cellular Materials for Structural Applications, Materials Research Society Proceeding, Vol. 521, MRS, Warrendale, PA, USA. Torobin (1983) Method and apparatus for producing hollow metal microspheres and microspheroids. US Patent No. 4,415,512. Uslu, C., Lee, K.J. Sanders, T.H. and Cochran, J.K. (1997) Ti–6AI–4V hollow sphere foams. In Synthesis/Processing of Light Weight Metallic Materials II, TMS, Warrendale, PA, USA. Wang et al. (1984) Apparatus for forming a continuous lightweight multicell material. US Patent No. 4,449,901. Wang et al. (1982) Method and apparatus for producing gas-filled hollow spheres. US Patent No. 4,344,787. Co-compaction or casting of two materials, one leachable De Ping, H.E., Department of Materials Science and Engineering, Southeast University, No. 2, Sipailu, Nanjing 210096, PR China (dphe@seu.edu.cn)
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 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: a) Metal - Hydrogen binary phase di
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?
Page 75 and 76: Table 6.1 Constitutive equations fo
Page 77 and 78: h SECTION h o h i d d o a b ;;; QQQ
Page 79 and 80: 6.3 Elastic deflection of beams and
Page 81 and 82: 6.4 Failure of beams and panels (a)
Page 83 and 84: ;; ;;; ;; M ;; ;;; ;; ;;; ;; ;; ;;
Page 85 and 86:
Torsion of shafts T T,q T T,q Yield
Page 87 and 88:
R a 2 Flow field R F R 2a 2 F F s c
Page 89 and 90:
;; ; QQ Q ¢¢ ¢ ;; ;; QQ QQ ¢¢
Page 91 and 92:
; ;; Creep p e p e • Area A u F 2
Page 93 and 94:
and its deviatoric (i.e. shear) com
Page 95 and 96:
Normalized effective stress 1.4 1.2
Page 97 and 98:
A constitutive model for metal foam
Page 99 and 100:
A constitutive model for metal foam
Page 101 and 102:
Stress amplitude, ∆σ + Stress,
Page 103 and 104:
Axial strain (%) 5 4 3 2 1 0 0 σma
Page 105 and 106:
Nominal compressive strain Nominal
Page 107 and 108:
σ max σ pl τ max τ pl σ max σ
Page 109 and 110:
Design for fatigue with metal foams
Page 111 and 112:
the net section stress criterion re
Page 113 and 114:
E σ pl (m) 10 1 0.1 0.01 0.1 Relat
Page 115 and 116:
Chapter 9 Design for creep with met
Page 117 and 118:
Design for creep with metal foams 1
Page 119 and 120:
instead to: � Pε 3 D Pε0 2 s Ł
Page 121 and 122:
Time to failure (hours) 10 2 10 1 1
Page 123 and 124:
Design for creep with metal foams 1
Page 125 and 126:
Chapter 10 Sandwich structures Sand
Page 127 and 128:
Sandwich structures 115 The elastic
Page 129 and 130:
Indentation Sandwich structures 117
Page 131 and 132:
H H Core shear Core shear Collapse
Page 133 and 134:
0.5 10−1 t c t c 10 −2 0.5 10
Page 135 and 136:
Sandwich structures 123 the contact
Page 137 and 138:
Sandwich structures 125 four sectio
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c t p p Figure 10.9 Sandwich panel
Page 141 and 142:
Sandwich structures 129 with k ¾ D
Page 143 and 144:
c/ Face sheet yielding 0.14 0.12 0.
Page 145 and 146:
Weight index, ψ 10 −1 10 −2 10
Page 147 and 148:
Sandwich structures 135 To construc
Page 149 and 150:
Sandwich structures 137 The associa
Page 151 and 152:
Sandwich structures 139 Note that,
Page 153 and 154:
where D � 2⊲1 Eft 2 f ⊳GcR Sa
Page 155 and 156:
Weight index ψ = W/2πR 2 ρ s W c
Page 157 and 158:
Sandwich structures 145 plastic yie
Page 159 and 160:
Sandwich structures 147 within the
Page 161 and 162:
Sandwich structures 149 Shuaeib, F.
Page 163 and 164:
Energy management: packaging and bl
Page 165 and 166:
Page 167 and 168:
Energy/Unit cost (kJ/£) 10 1 0.1 0
Page 169 and 170:
Page 171 and 172:
ys crushes axially at the load Ener
Page 173 and 174:
Page 175 and 176:
Page 177 and 178:
Page 179 and 180:
peak pressure MPa Impulse/(mass of
Page 181 and 182:
Page 183 and 184:
Chapter 12 Sound absorption and vib
Page 185 and 186:
Sound absorption and vibration supp
Page 187 and 188:
Page 189 and 190:
0 Sound absorption and vibration su
Page 191 and 192:
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 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 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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