Metallic Foams II:: Properties and Applications

Metallic Foams II:
Properties and Applications
John Banhart
1
Metallic Foams II Properties & Applications
Hahn-Meitner-Institut Berlin
What is a metal foam?
high porosity: > 80% closed cells usually quite irregular metallic matrix: mostly Al alloy
60 mm
Metallic Foams II Properties & Applications 3
Properties
Properties of cellular metals - overview
class mechanical
Property Elastic behaviour Anelastic behaviour Plastic behaviour
Observable Youngs modulus Shear modulus Loss factor Shear strength Bending strength Energy absorption Compressive/tensile strength
static/ dynamic
E G
c t b E abs ( ) ,
electrical thermal acoustic dynamic
Electrical conduction Thermal expansion Thermal conduction Sound absorption
Electrical conductivity Expansion coefficient Thermal conductivity Sound absorption coeffiecient Filter parameters
aero- / hydro- Flow properties
Behaviour of aluminium foams under compression
AlSi6Cu4 foams varying density

Spannung (MPa) stress (MPa)
70 60 50 40 30 20 10 0 0
=0.39 g/cm =0.44 g/cm =0.54 g/cm =0.58 g/cm
3 3 3 3
40 x 40 x 40 mm3 2 face sheets
Extended plateau regime at high stresses
20
40 Stauchung strain (%) (% )
60
80
Deformation of aluminium alloy foam
Ductile foam
Brittle foam
video
video
Micro-mechanisms Cell wall buckling and shearing
0% strain
25.3% strain
distortion & shearing
distortion
c
Mixture of cell distortion and shear observed

Buckle
Micro-mechanisms fatigue cracks
cracks
SEM pictures of foam cells taken after 4% deformation of the foam
Deformation of metallic foams
Foams can be loaded in three principal modes:
Free foam
Some studies available: see Ashby book and more recent papers
Foam in conjunction with section or face sheets
Some studies available, see e.g. Hansen and Langseth
Foam in section, but load only on foam: section acts as constraint only
No study so far
Deformation with and without constraint
10
constraint
Lateral constraint
11
Steel sleeve (right) and aluminium block (left) used for conducting tests with constraint
Sample 2 X-ray radiography
12
quasi-static testing with constraint
video unstrained
video 28% static strain
Effect of constraint on static compression behaviour
13
*=10.2%
Constraint induces strain hardening through - triaxial nature of stress - friction between constraint walls and foam.
* Kolluri et al., Met. Mat. Trans 38A, 2006 (2007)
Definition of problem
14
all solid
solid liquid
all solid
T
natural cooling forced cooling
t Problem with solution heat treatment:

heat in foam has to be conducted through face sheet quenching in water not feasible water intrusion + warping low quenching rate insufficient T6 not achievable question: can some degree of age hardening be reached starting from a not perfectly quenched state? T5
Heat treatment of AFS
15
115,2 120
Hardness (HV)
100 80 60 40 20 0 As Fabricated 57,9
87,7
Micro-hardness different heat treatments 6082 face sheet of AFS

T 5-Heat treated T6-Heat treated
Conditions
natural cooling
natural cooling + age hardening = T5
forced cooling + age hardening = T6
Metallic Foams II Properties & Applications 16
Applications
Application fields for aluminium foams
17
density stiffness
strength shape - curve

light-weight construction energy absorption
bifunctional application
damping insulation
ideal multifunctional application
mechanical damping thermal conductivity acoustic properties
Comparison: dense metal vs. foamed metal
18
dense sheet
1
foam is much stiffer than sheet at same mass
foam
5
optimisation
same mass and same height
optimisation
waffel plate
waffle plate is stiffer (or honeycomb, stringer stiffened structure )
foam core sandwich panel
M.F. Ashby et al., Metal Foams - A Design Guide, p. 139
but .....
19
Other aspects relevant for comparison: manufacture of complex shapes (3D) possible cost elastic limit failure mode damage tolerance integration into system joining technology other aspects, e.g. mechanical, acoustic electromagnetic damping ... Advantage for AFS in some cases
Aluminium Foam Sandwich panels (AFS)
20
IFAM
Al foam core
steel face sheets
alm
dense face sheets (Al, steel, Ti)

30 cm
10
AFS development
21
AFS prototype 1992
12 x 8 cm
area 200
AFS production 2007
Metal foam + dense metal = composite IFAM
22
Alulight
F. Simank
HKB
11
Compression behaviour of foams
23
70 60 stress [MPa] 50 40 30 20 10 0
0 10 20 30 40 50 60 70
2,4 2,0 stress [MPa] 1,6 AlCu4

porosity 83%
compare polyethylen foam (PE) metal foam (AlCu4)
1,2 PE
porosity 87%
0,8 0,4 0,0
about same relative density Al-foam stronger: 30
strain (%)
Absorption of mechanical energy by metal foam
24
100 deformation force [kN] 80 60 40 20 0 absorbed energy at 25 mm deformation length =1300 J ideal absorber for 60 kN maximum force Eabs = 1500 J
efficiency = 87%
video
0 5 10 15 20 25 deformation length [mm] 30 35
12
Compression strength as a function of density
25
20 strength [MPa] 10 8 6 4
n=1,670,18
F
x2
I
n=1,890,08
2 1 0,1
orientation I orientation II
F
0,8 1
0,2
0,4 density [g/cm ]

3
0,6
II
Application idea: front impact absorber
26
impact energy is absorbed in crash box before longitudinal member is deformed exchangeable elements facilitate repair after lowvelocity crashs and reduce costs
Patent-OS DE 1-95.02 307, Gerhardi & Cie.
t n te a p
light-weight construction
energy absorption
13
Front impact energy absorber for COMBINO tram car
27
600 mm
Se r ia la
pp lic
at io n!
energy absorption
Schunk Siemens - Hbner
Stiffener in door sill
28
Alulight
Se r ia la
pp l ic
at io n!
energy absorption
14
Support structure of a telescope working platform
29
Euro-B drivers licence

less than 3500 kg total weight
+legislation
25 m working height 11 m outreach
a art l ia 00 p r Se 1
l ea p p s/y
! n io t i ca r
Support structure of a telescope working platform
30
EURO B25 T mass 110 kg height 2441 mm 50% lighter than steel arm production volume: 60-100 pc./yr.
15
Manufacture of support structure
31
AFS
6 AFS panels, sawed to shape welded to each other by MIG+TIG AFS rim sealed with Al sheets inset glued into hole
Life cycle test of support structure
32
Cyclic multiaxial load: 100 kN ||c 14 kN Requirement: N = 40.000 Result: no cracks up to N = 100.000
Test rig
16
Alimex high precision plates
33
Alimex is manufacturer of high precision low residual stress aluminium plates

ACP series: cast plates AMP series rolled plates
New:
AFP: foamed AFS plate
Alimex high precision plates
34
Properties

face sheets: 5083 alloy, 6 mm thick foam density: 0.4 g/cm3 AFS: 2000 x 1000 mm; 30 to 60 mm thick light 70 to 50% (w.r.t. Al) stiffness 8% cost +30% weldable, application temperature range -220 to 540C
Advantages

Applications (as given by

metrology platforms for milling machines and tooling fire protection in trains and ships
17
Ariane rocket cone
35
Existing part: aluminium honeycomb + Al ring Too expensive!
Ariane Rocket Cone 3936 AFS replacement
36
Dimensions
Upper diameter 2624 mm Lower diameter 3936 mm Total weight: 180 kg
12 Segments 1200x1200x25 mm face sheet s 1.3 mm thick
1200 mm
Technology:
3D foamed AFS 6060 + AlCu6Cu6 TIG welded, manually 1200 mm
18
Ariane rocket cone: prototype assembly.
37
Test facilities for Ariane rocket cone
38
ro p Test Load up to 10 t normal to cone

10 t in plane of the upper ring Status: optimisation necessary
e p ty o t
0.03 mm elastic deformation (15% too high)
19
Bicycle crank arm (Prototype)
39
Forged 6062
AFS
o r p
e p ty o t
Conventional Al crank arm: 313 g, AFS crank arm: 222 g = 30%

7g lighter than 2nd lightest product
direct substitution, design adapted to AFS will further improve
Crash element in safety guard
40
Se ri 10 al 0 a
,0 00
pp pa lic
rts
stress (MPa)
Serial production of safety relevant part in Audi Q7 pikes peak Limits forces to 1.5 kN at 50% deformation (of 73 mm)
/y tio ea r n!
energy absorption
strain (%)
20
Application idea based on strength and damping
41
o r p
IFAM Bremen
eGear-wheel with an p ty anti-vibration layer of o t aluminium foam

damping insulation
Truck cabin
42
Steel-based total mass 294 kg
o pr
e p ty o t
AFS-based total mass 220 kg
weight reduction > 30% increase in stiffness > 15 % better crash behaviour
21
Truck cabin - individual parts
43
AFS-Parts
AFS-Parts
Engine bracket for BMW
44
energy absorption
damping insulation
o pr
e p ty o t
22
CASTOR containers for radioactive waste
45
video
o r p
Container after falling from 9m height
e p ty o t
damping insulation
+ non-inflammability
Functional applications for open-cell structures (1)
46
Al (infiltrated) soft slide
sound damper heat exchanger transpiration cooler slip surfaces
AlSi20Fe5Ni2 hard matrix
23
Functional applications for open cell structures (2)
47
Applications:
catalyst support oxidation resistant structures, filtration bio-compatible implant structures
cell Size: 0.2-2.5mm
/s: 2-10%
Landscape of metal foam research
48
Processing of metal foams manufacture of parts

new processing opportunities
materials
Metal foam properties

mechanical behaviour functional properties
knowledge
questions
requirements
SP relationships
Physics of metal foaming

stabilisation kinetics ...
Structure of metal foams

Topology Cell parameter distributions
24
What to read
49
M.F. Ashby, A.G. Evans, N.A. Fleck, L.J. Gibson, J.W. Hutchinson, H.N.G. Wadley Metal Foams - A Design Guide Butterworth-Heinemann (2000)
J. Banhart, M.F. Ashby, N.A. Fleck: MetFoam1999 J. Banhart, M.F. Ashby, N.A. Fleck: MetFoam2001 J. Banhart, N.A. Fleck, A. Mortensen: MetFoam2003 H. Nakajima, N. Katetake: Metfoam2005 L.-P. Lefebvre, J. Banhart, D. Dunand: Metfoam2007
Where to go in the internet and in the real world?
50
http://www.metalfoam.net
6th International Conference MetFoam2009 Bratislava, 2.-4.9.2009
banhart@helmholtz-berlin.de
25
Work at the department Materials
51
The team comprises 4 working groups:
metal foams, microstructure, imaging, scattering 1 Professor, 2 Lecturers, 6 Senior scientists, 4 Postdocs, 8 PhD students, 4 Diploma/MSc students + Students + 5 Technicians, 1 Secretary
About 25 researchers
We offer open positions on http://www.hmi.de/bereiche/SF/SF3/job_opportunities/index_en.htm

52
video
Thank you!
26

Metallic Foams II:: Properties and Applications

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Metallic Foams II:

Properties and Applications

Metallic Foams II Properties & Applications

What is a metal foam?

Metallic Foams II Properties & Applications 3

Metallic Foams II Properties & Applications

Properties of cellular metals - overview

Property Elastic behaviour Anelastic behaviour Plastic behaviour

electrical thermal acoustic dynamic

Electrical conduction Thermal expansion Thermal conduction Sound absorption

aero- / hydro- Flow properties

Metallic Foams II Properties & Applications

Behaviour of aluminium foams under compression

AlSi6Cu4 foams varying density

=0.39 g/cm =0.44 g/cm =0.54 g/cm =0.58 g/cm

40 x 40 x 40 mm3 2 face sheets

Extended plateau regime at high stresses

40 Stauchung strain (%) (% )

Metallic Foams II Properties & Applications

Deformation of aluminium alloy foam

Metallic Foams II Properties & Applications

Micro-mechanisms Cell wall buckling and shearing

distortion & shearing

Mixture of cell distortion and shear observed

Metallic Foams II Properties & Applications

Micro-mechanisms fatigue cracks

SEM pictures of foam cells taken after 4% deformation of the foam

Metallic Foams II Properties & Applications

Deformation of metallic foams

Foams can be loaded in three principal modes:

Foam in conjunction with section or face sheets

Some studies available, see e.g. Hansen and Langseth

Metallic Foams II Properties & Applications

Deformation with and without constraint

Metallic Foams II Properties & Applications

Metallic Foams II Properties & Applications

Sample 2 X-ray radiography

quasi-static testing with constraint

video 28% static strain

Metallic Foams II Properties & Applications

Effect of constraint on static compression behaviour

Metallic Foams II Properties & Applications

t Problem with solution heat treatment:

Metallic Foams II Properties & Applications

Heat treatment of AFS

100 80 60 40 20 0 As Fabricated 57,9

Micro-hardness different heat treatments 6082 face sheet of AFS

natural cooling + age hardening = T5

forced cooling + age hardening = T6

Metallic Foams II Properties & Applications 16

Metallic Foams II Properties & Applications

Application fields for aluminium foams

strength shape - curve

ideal multifunctional application

mechanical damping thermal conductivity acoustic properties

Metallic Foams II Properties & Applications

Comparison: dense metal vs. foamed metal

foam is much stiffer than sheet at same mass

same mass and same height

foam core sandwich panel

M.F. Ashby et al., Metal Foams - A Design Guide, p. 139

Metallic Foams II Properties & Applications