Metal Foams: A Design Guide

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10.5 Weight-efficient structures 124 10.6 Illustration for uniformly loaded panel 126 10.7 Stiffness-limited designs 133 10.8 Strength-limited designs 140 10.9 Recommendations for sandwich design 148 References 148 11 Energy management: packaging and blast protection 150 11.1 Introduction: packaging 150 11.2 Selecting foams for packaging 151 11.3 Comparison of metal foams with tubular energy absorbers 157 11.4 Effect of strain rate on plateau stress 161 11.5 Propagation of shock waves in metal foams 163 11.6 Blast and projectile protection 166 References 169 12 Sound absorption and vibration suppression 171 12.1 Background: sound absorption in structural materials 171 12.2 Sound absorption in metal foams 173 12.3 Suppression of vibration and resonance 175 References 179 13 Thermal management and heat transfer 181 13.1 Introduction 181 13.2 Heat transfer coefficient 182 13.3 Heat fluxes 184 13.4 Pressure drop 186 13.5 Trade-off between heat transfer and pressure drop 187 References 188 14 Electrical properties of metal foams 189 14.1 Measuring electrical conductivity or resistivity 189 14.2 Data for electrical resistivity of metal foams 190 14.3 Electrical conductivity and relative density 191 References 193 15 Cutting, finishing and joining 194 15.1 Cutting of metal foams 194 15.2 Finishing of metal foams 194 15.3 Joining of metal foams 195 References 199 16 Cost estimation and viability 200 16.1 Introduction: viability 200 16.2 Technical modeling and performance metrics 201 16.3 Cost modeling 202 16.4 Value modeling 206 16.5 Applications 212 References 216 Contents vii
viii Contents 17 Case studies 217 17.1 Aluminum foam car body structures 217 17.2 Integrally molded foam parts 219 17.3 Motorway sound insulation 220 17.4 Optical systems for space applications 222 17.5 Fluid–fluid heat exchangers 224 17.6 Lightweight conformal pressure tanks 225 17.7 Electrodes for batteries 225 17.8 Integrated gate bipolar transistors (IGBTs) for motor drives 226 17.9 Applications under consideration 232 18 Suppliers of metal foams 234 19 Web sites 239 Appendix: Catalogue of material indices 242 Index 247
Page 1 and 2: Metal Foams: A Design Guide
Page 3 and 4: Copyright © 2000 by Butterworth-He
Page 5: vi Contents 4.3 Foam property chart
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 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
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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
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
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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
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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
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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
Page 201 and 202:
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
Page 217 and 218:
$/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
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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