• Title, Summary, Keyword: Aluminum Foam

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Fracture Behavior of Adhesive-Bonded Aluminum Foam with Double Cantilever Beam (접착제로 접합된 이중외팔보 알루미늄폼의 파괴 거동에 관한 연구)

  • Bang, Hye-Jin;Lee, Sang-Kyo;Cho, Chongdu;Cho, Jae-Ung;Choi, Hae-Kyu
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.38 no.5
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    • pp.521-526
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    • 2014
  • In this study, closed-cell aluminum foam with an initial crack was investigated to produce an axial load-time graph. Using the 10-kN Landmarks of MTS Corporation, a 15-mm/min velocity of mode I shape was applied to the aluminum foam specimen using the displacement control method. ABAQUS 6.10 simulation was used to model and analyze the identical model in three dimensions under conditions identical to those of the experiment. The energy release rate was calculated on the basis of an axial load-displacement graph obtained from the experiment and a transient image of the crack length, and then an FE model was analyzed on the basis of this fracture energy condition. The relation between load and displacement was discussed; it was found that the aluminum foam deformed somewhat less than the adhesive layer owing to the difference in elastic modulus.

Density and Mechanical Properties of Aluminum Lost Foam Castings (알루미늄 합금 소실모형주조재의 밀도 및 기계적 성질)

  • Kim, Ki-Young;Oh, Don-Suk;Choe, Kyeong-Hwan;Cho, Gue-Serb;Lee, Kyung-Whoan
    • Journal of Korea Foundry Society
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    • v.24 no.2
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    • pp.94-100
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    • 2004
  • Gas porosity which is a common defect in aluminum alloy casting, is also thought to be severer in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring. Fundamental experiments were carried out to evaluate the effect of process variables such as the melt treatment, the cooling rate and pouring temperature on the density and mechanical properties in A356.2 castings with simple bar shape. The density of grain refined specimen was slightly lower than that of degassed one, but was higher than that of no treated one and that of shot ball packed specimen was higher than the other specimens. The tensile strength and elongation were in the ranges of $200{\sim}230MPa$ and $0.5{\sim}1.5%$ respectively. The density and hardness of lost foam cast specimens decreased with increase in pouring temperature.

Analysis of 3D Geometry and Compressive Behavior of Aluminum Open Cell Foam Using X-ray Micro CT (마이크로 X-ray CT를 활용한 알루미늄 개방형 폼의 형상 및 압축 거동 분석)

  • Kim, Y.I.;Kim, J.H.;Lee, J.K.;Kim, D.
    • Transactions of Materials Processing
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    • v.20 no.7
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    • pp.518-523
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    • 2011
  • The three dimensional geometries of an aluminum open cell foam before and after uniaxial compressive loading were investigated using the X-ray micro CT(computed tomography). Aluminum 6101-T6 open cell foams of 10, 20, 40 ppi (pore per inch) were considered in this work. After the serial sectioning CT images of aluminum foams were obtained from non-destructive X-ray images, the exact 3D structure were reproduced and visualized with commercial image processing program. The relative density ratio was around the 7.0 to 9.0 range, the unit cells showed anisotropic shapes having the different dimensional ratios of 1.1 to 1.3 between the rise and the transverse directions. The yield stress increased with the relative density ratio and the volumetric strain increased proportionally with compressive strain. The plateau stress in the compressive stress-strain curve was caused by the buckling of ligaments.

Effects of face-sheet materials on the flexural behavior of aluminum foam sandwich

  • Xiao, Wei;Yan, Chang;Tian, Weibo;Tian, Weiping;Song, Xuding
    • Steel and Composite Structures
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    • v.29 no.3
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    • pp.301-308
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    • 2018
  • Properties of AFS vary with the changes in the face-sheet materials. Hence, the performance of AFS can be optimized by selecting face-sheet materials. In this work, three types of face-sheet materials representing elastic-perfectly plastic, elastic-plastic strain hardening and purely elastic materials were employed to study their effects on the flexural behavior and failure mechanism of AFS systematically. Result showed face-sheet materials affected the failure mechanism and energy absorption ability of AFS significantly. When the foam cores were sandwiched by aluminum alloy 6061, the AFS failed by face-sheet yielding and crack without collapse of the foam core, there was no clear plastic platform in the Load-Displacement curve. When the foam cores were sandwiched by stainless steel 304 and carbon fiber fabric, there were no face-sheet crack and the sandwich structure failed by core shear and collapse, plastic platform appeared. Energy absorption abilities of steel and carbon fiber reinforced AFS were much higher than aluminum alloy reinforced one. Carbon fiber was suggested as the best choice for AFS for its light weight and high performance. The versus strength ratio of face sheet to core was suggested to be a significant value for AFS structure design which may determine the failure mechanism of a certain AFS structure.

Interfacial Characteristics of Al-Cu Cast Composites for High Conductivity Applications (고전도성 부품용 Al-Cu 주조복합재료의 계면 특성)

  • Kim, Jeong-Min;Kim, Nam-Hoon;Ko, Se-Hyun
    • Journal of Korea Foundry Society
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    • v.38 no.3
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    • pp.55-59
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    • 2018
  • To optimize the conductivity and to reduce the weight by as much as possible, Al-Cu composites were prepared through a suction-casting procedure. Pure copper metal foam was infiltrated by melted aluminum with the use of the vacuum, after which warm rolling was conducted to remove several remaining pores at the interface between the Cu foam and the aluminum matrix. Despite the short casting time, significant dissolution of Cu into the melt was observed. Moreover, it was found that various Al-Cu intermetallic compounds arose at the interface during the isothermal heating process after the casting and rolling steps. The average thickness of the Al-Cu intermetallic compound tended to increase in proportion to the heating time. The electrical and thermal conductivity levels of the cast composites were found to be comparatively low, mainly due to the dissolution of the Cu foam and the formation of intermetallics at the interface.

Effects of Process Parameters on Cell Control of Aluminum Foal Material (알루미늄 발포소재의 성형 공정 인자가 기공제어에 미치는 영향)

  • 전용필;강충길
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.163-166
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    • 1997
  • Aluminium foam material is a highly porous material having complicated cellular structure defined by randomly distributed air pores in metallic matrix. this structure gives the aluminium a set of properties which cannot be achieved by any of conventional treatments. The properties of aluminium foam material significantly depend on its porosity, so that a desired profile of properties can be tailored by changing the foam density. Melting method is the one of foaming processes, which the production has long been considered difficult to realize becaues of such problems as the low foamability of molten metal, the varying size of. cellular structures, solidification shrinkage and so on. These problems, however, have gradually been solved by researchers and some manufacturers are now producing foamed aluminum by their own methods. Most of all, the parameters of solving problem in electric furnace were stirring temperature, stirring velocity, foaming temper:iture, and so on. But it has not considered about those in induction heating, foaming velocity and foaming temperature in semi-solid state yet. Therefore, this paper presents the effects on these parameter to control cell size, quantity and distribution.

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The Effect of Zr Addition on AM50 Mg Alloys Foam Metals (AM50 Mg합금 발포금속의 제조와 지르코늄 첨가 영향)

  • Kim, Byeong-Gu;Tak, Byeong-Su;Hur, Bo-Young
    • Journal of Korea Foundry Society
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    • v.30 no.6
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    • pp.217-223
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    • 2010
  • Foamed metal has become an attractive material, which has unique physical, thermal, acoustic, damping and mechanical properties, because large amount of pores are distributed in the metal matrix. Therefore, metal foam can be used for the light weight application in automotive, locomotive, aerospace fields. Aluminum foams have been developed successfully and will be employed in the next generation of energy absorption boxes. Magnesium alloys are most eligible candidate to substitute aluminum alloy, especially for lower density and higher damping properties in wide industrial fields. Magnesium alloy foams are expected to be particularly advantageous due to two thirds the density of aluminum. However, foaming magnesium have been weakness of high activity, difficult processing and very dangerous. In order to upgrade this problem, AM50 magnesium alloy which has better characteristic is safe to use through foaming time and alloying element in this study.

Heat Flow of Round Jet Impinging Aluminum Foam Mounted on the Heated Plate with Constant Heat Flux (균일한 열유속을 갖는 가열된 평판에 부착된 발포알루미늄에 대한 원형 충돌제트의 열유동 특성)

  • Han, Young-Hee;Lee, Kye-Bock;Lee, Chung-Gu
    • Journal of Energy Engineering
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    • v.18 no.2
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    • pp.108-113
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    • 2009
  • An experimental study of jet impingement on aluminum foam mounted on the surface with constant heat flux is conducted with the presentation of the heat transfer rate measured when jet impinges normally to a flat plate. Effects of pore density, foam thickness and Reynolds number on the heat transfer are analyzed. Experimental results show that the significant enhancement in Nu is obtained when the aluminum foam is mounted on the heated plate and that the increase in the heat transfer due to the porous material insertion is dominated by both the increase in the heat transfer area and the decrease in the momentum flux resulted from the pressure drop.

Ballistic impact analyses of triangular corrugated plates filled with foam core

  • Panigrahi, S.K.;Das, Kallola
    • Advances in Computational Design
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    • v.1 no.2
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    • pp.139-154
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    • 2016
  • The usage of sandwich structure is extensively increasing in lightweight protective structures due to its low density and other useful properties. Sandwich panels made of metal sheets with unfilled cellular cores are found to exhibit lower deflections by comparing to an equivalent monolithic plate of same metal and similar mass per unit density. However, the process of localized impact on solid structures involving plastic deformation, high strain rates, temperature effect, material erosion, etc. does not hold effectively as that of monolithic plate. In present work, the applications of the sandwich plate with corrugated core have been extended to develop optimized lightweight armour using foam as medium of its core by explicit finite element analysis (FEA). The mechanisms of hardened steel projectile penetration of aluminum corrugated sandwich panels filled with foams have been numerically investigated by finite element analysis (FEA). A comparative study is done for the triangular corrugated sandwich plate filled with polymeric foam and metallic foam with different densities in order to achieve the optimum penetration resistance to ballistic impact. Corrugated sandwich plates filled with metallic foams are found to be superior when compared to the polymeric one. The optimized results are then compared with that of equivalent solid and unfilled cores structure to observe the effectiveness of foam-filled corrugated sandwich plate which provides an effective resistance to ballistic response. The novel structure can be the alternative to solid aluminum plate in the applications of light weight protection system.

Fabrication of Aluminum Foams for High Profit Recycling of Aluminum Can Scraps (알루미늄 캔 스크랩의 고품위 재활용을 위한 발포금속의 제조)

  • Ha, Won;Kim, Shae-Kwang;Kim, Young-Jig
    • Journal of Korea Foundry Society
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    • v.25 no.5
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    • pp.203-208
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    • 2005
  • The main emphasis of this study is to optimize the process variables for manufacturing aluminum foam materials by direct foaming of remelted aluminum scraps. Aluminum foams were fabricated from two different raw materials, pure aluminum and used beverage cans. For both cases, $TiH_{2}$ was used as a foaming agent. Calcium was added as a thickener for the foaming of pure aluminum and no thickener was added for that of used beverage Cans because the pre-existing oxides of the used beverage cans are used as a thickener. Calcium and $TiH_{2}$ content varies from 0.5wt.% to 2.0wt.% and from 0.5wt.% to 1.5wt.%, respectively. The processing conditions, such as the effect of calcium on the melt viscosity, foaming temperature, and the optimum amount of the foaming agent with regard to the melt viscosity were discussed.