Numerical Study on Fluid Flow Behavior and Heat Transfer Performance of Porous Media Manufactured by a Space Holder Method.

The velocity field and temperature field are crucial for metal foams to be used as a heat exchanger, but they are difficult to obtain through physical experiments. In this work, the fluid flow behavior and heat transfer performance in open-cell metal foam were numerically studied. Porous 3D models with different porosities (55-75%) and pore sizes (250 µm, 550 µm, and 1000 µm) were created based on the porous structure manufactured by the Lost Carbonate Sintering method. A wide flow velocity range from 0.0001 m/s to 0.3 m/s, covering both laminar and turbulent flow regimes, is fully studied for the first time. Pressure drop, heat transfer coefficient, permeability, form drag coefficient, temperature and velocity distributions were calculated. The calculated results agree well with our previous experimental results, indicating that the model works well. The results showed that pressure drop increased with decreasing porosity and increasing pore size. Permeability increased and the form drag coefficient decreased with increasing porosity, and both increased with increasing pore size. The heat transfer coefficient increased with increasing velocity and porosity, whereas it slightly decreased with increasing pore size. The results also showed that at high velocity, only the metal foam close to the heat source contributes to heat dissipation.

Effects of the Space Holder Shape on the Pore Structure and Mechanical Properties of Porous Cu with a Wide Porosity Range.

Porous copper (Cu), with varying porosities, has been made using carbamide as a space holder through the powder metallurgy route. Two shapes of carbamide particles were used, (i) needlelike and (ii) spherical, in order to investigate the effect of the space holder shape on the pore structure and mechanical properties of porous Cu. The compressive deformation behavior of porous Cu was studied under a compression test. The pores' structural characteristics and mechanical properties of the porous Cu varied significantly with the shape of the space holder. Although the effect of the space holder shape on the porosity was not regular, the effect on the mechanical properties was regular. The stress increased monotonically with the increase in the strain, and strain hardening occurred at the plastic yield stage. The elastic modulus and yield strength followed the power law, with the relative density irrespective of the space holder shape. The empirical constants associated with different empirically developed power law relations were different, according to the shape of space holder. A quantitative relationship between the elastic modulus and yield strength and the spacer content was obtained to control the mechanical properties of the present porous Cu or other porous metals and metal foams using the well-known space holder method.

Optimizing of a metal foam-assisted solar air heater performance: a thermo-hydraulic analysis of porous insert placement.

A numerical assessment of the heat transfer efficacy of a solar air heater (SAH) was carried out. The SAH is supplied with a porous metal foam layer to improve thermal mixing. Both the local thermal non-equilibrium (LTNE) and Darcy-extended Forchheimer (DEF) models were employed to forecast fluid and thermal transport within the partly filled SAH channel. The analysis was performed for various values of dimensionless foam layer lengths ( S = 0 - 1 ), pore densities ( ω = 10 - 40 PPI ), and Reynolds numbers ( R e = 4000 - 1 6 , 000 ) at a fixed value of layer thickness ( H f = 0.6 ). Based on the position of the porous layer, three distinct arrangements, marked as Case 1, Case 2, and Case 3, were explored. Regarding the parameters examined, the findings indicate a definite improvement in the average Nusselt number ( Nu ), but unfortunately, the friction factor also increases unfavorably. By reducing the length of the porous layer, a reasonable reduction in heat transfer rate and a significant decrease in pressure drop were noticed. The results showed about 26.64%, 48.73%, and 70.74% reductions in pressure drop by reducing the dimensionless foam length from 1 to 0.25, 0.5, and 0.75 respectively for ω = 10 at R e = 16 , 000 . On the other side, there are only about 11.05%, 23.11%, and 40.78% reductions in Nu . The exhaustive analysis of the thermal performance of SAH was conducted using the thermal performance factor (TPF), which considers the trade-off between the SAH channel's potential for improved heat transmission and its cost for pressure loss. The TPF may reach a maximum of 2.82 compared to the empty channel when the metal foam layer is inserted with S = 1 , for ω = 10 , and R e = 16 , 000 .

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review.

Closed-cell aluminum foams have many excellent properties, such as low density, high specific strength, great energy absorption, good sound absorption, electromagnetic shielding, heat and flame insulation, etc. As a new kind of material, closed-cell aluminum foams have been used in lightweight structures, traffic collision protections, sound absorption walls, building decorations, and many other places. In this paper, the recent progress of closed-cell aluminum foams, on fabrication techniques, including the melt foaming method, gas injection foaming method, and powder metallurgy foaming method, and on processing techniques, including powder metallurgy foaming process, two-step foaming process, cast foaming process, gas injection foaming process, mold pressing process, and integral foaming process, are summarized. Properties and applications of closed-cell aluminum foams are discussed based on the mechanical properties and physical properties separately. Special focuses are made on the newly developed cast-forming process for complex 3D parts and the improvement of mechanical properties by the development of small pore size foam fabrication and modification of cell wall microstructures.

Highly sensitive analysis of trace germanium derived from the efficient electrosynthesis and spectral introduction of GeH4 on foam electrode.

BACKGROUND: The electrochemical hydride generation technology, which uses electrolysis instead of chemical reagents to generate reducing species to achieve gaseous transformation and sample introduction of the tested elements, has received widespread attention in the field of atomic spectroscopy due to its simple, economical, and green characteristics. However, limited by the effective area of the electrode, the introduction efficiency and spectral signal of most elements (e.g., germanium) in practical applications are lower than traditional chemical hydride generation. RESULTS: In this paper, an efficient electrochemical hydride generation (EHG) method based on metal foam electrode for µg L-1 level germanium was constructed. Systematic electrochemical and spectral tests showed that the low charge transfer resistance and the high electrochemical activity of nickel-based foam electrodes jointly promoted the efficient electroreduction of Ge(IV). Besides, the porous network structure of the metal foam material improves the contact probability of reactants while reducing the gas-evolution effect caused by bubble accumulation. Interestingly, adequate reaction sites are crucial for the conversion of germanium, but large foam electrodes are not always compatible with analytical performance. After coupling atomic fluorescence spectroscopy, this new electrolysis method has been proven to be suitable for efficient conversion and quantitative detection of Ge over a wide concentration range (5-150 µg L-1). SIGNIFICANCE: Our proposal to improve the electrosynthesis efficiency of germanane (GeH4) by using metal foam electrode is extremely effective for the detection of trace or ultra-trace germanium. The exploration of electrode material, structure, and especially effective area will also provide ideas for the establishment of highly sensitive analysis methods in the future.

Self-Standing Metal Foam Catalysts for Cathodic Electro-Organic Synthesis.

Although electro-organic synthesis is currently receiving renewed interest because of its potential to enable sustainability in chemical processes to value-added products, challenges in process development persist: For reductive transformations performed in protic media, an inherent issue is the limited choice of metallic cathode materials that can effectively suppress the parasitic hydrogen evolution reaction (HER) while maintaining a high activity toward the targeted electro-organic reaction. Current development trends are aimed at avoiding the previously used HER-suppressing elements (Cd, Hg, and Pb) because of their toxicity. Here, this work reports the rational design of highly porous foam-type binary and ternary electrocatalysts with reduced Pb content. Optimized cathodes are tested in electro-organic reductions using an oxime to nitrile transformation as a model reaction relevant for the synthesis of fine chemicals. Their electrocatalytic performance is compared with that of the model CuSn7Pb15 bronze alloy that has recently been endorsed as the best cathode replacement for bare Pb electrodes. All developed metal foam catalysts outperform both bare Pb and the CuSn7Pb15 benchmark in terms of chemical yield and energetic efficiency. Moreover, post-electrolysis analysis of the crude electrolyte mixture and the cathode's surfaces through inductively coupled plasma mass spectrometry (ICP-MS) and scanning electron microscopy (SEM), respectively, reveal the foam catalysts' elevated resistance to cathodic corrosion.

Thermal Management of Microelectronic Devices Using Nanofluid with Metal foam Heat Sink.

Microelectronic components are used in a variety of applications that range from processing units to smart devices. These components are prone to malfunctions at high temperatures exceeding 373 K in the form of heat dissipation. To resolve this issue, in microelectronic components, a cooling system is required. This issue can be better dealt with by using a combination of metal foam, heat sinks, and nanofluids. This study investigates the effect of using a rectangular-finned heat sink integrated with metal foam between the fins, and different water-based nanofluids as the working fluid for cooling purposes. A 3D numerical model of the metal foam with a BCC-unit cell structure is used. Various parameters are analyzed: temperature, pressure drop, overall heat transfer coefficient, Nusselt number, and flow rate. Fluid flows through the metal foam in a turbulent flow with a Reynold's number ranging from 2100 to 6500. The optimum fin height, thickness, spacing, and base thickness for the heat sink are analyzed, and for the metal foam, the material, porosity, and pore density are investigated. In addition, the volume fraction, nanoparticle material, and flow rate for the nanofluid is obtained. The results showed that the use of metal foam enhanced the thermal performance of the heat sink, and nanofluids provided better thermal management than pure water. For both cases, a higher Nusselt number, overall heat transfer coefficient, and better temperature reduction is achieved. CuO nanofluid and high-porosity low-pore-density metal foam provided the optimum results, namely a base temperature of 314 K, compared to 341 K, with a pressure drop of 130 Pa. A trade-off was achieved between the temperature reduction and pumping power, as higher concentrations of nanofluid provided better thermal management and resulted in a large pressure drop.

Optimized design and experimental validation of sound absorption coefficient performance in aluminium metal foam by spark plasma sintering.

Determining the structural properties of aluminum metal foam is essential to predicting its acoustic behavior. Acoustic models are presented that show the relationship between the morphology of the absorber and the sound absorption coefficient (SAC). Optimizing the parameters affecting the SAC can be the maximum theoretically SAC achieved at each frequency. In the previous article (https://doi.org/10.32604/sv.2021.09729) the parameters of porosity percentage (Ω), pore size (D) and pore opening size (d) were optimized by the genetic algorithm and Lu model. In this study, the optimal aluminum metal foam was synthesized using Spark Plasma Sintering (SPS), with the maximum temperature of 420 °C and final pressure of 20 MPa in samples with thicknesses of 5, 10, 15 and 20 mm in different frequencies from 1000 to 6300 Hz. The crystal structure and microstructure of samples were investigated using XRD and SEM. Optimized metal foam SAC (0.67, 0.9, 1 and 1) and experimental peak SAC (0.44, 0.67, 0.76 and 0.82) were compared with the optimized SAC in 5, 10, 15 and 20 mm thicknesses, respectively. The values of the coefficient of determination (R2) according to multiple linear regression (MLR) for the two optimized SAC and experimental in thicknesses of 5, 10, 15 and 20 mm were 0.90, 0.95, 0.96 and 0.90, respectively. The results of this study show that porous metal foam can have a high absorption coefficient in any desired thickness and frequency by using the optimal morphology.

Water Management Capacity of Metal Foam Flow Field for PEMFC under Flooding Situation.

Porous metal foam with complex opening geometry has been used as a flow field to enhance the distribution of reactant gas and the removal of water in polymer electrolyte membrane fuel cells. In this study, the water management capacity of a metal foam flow field is experimentally investigated by polarization curve tests and electrochemical impedance spectroscopy measurements. Additionally, the dynamic behavior of water at the cathode and anode under various flooding situations is examined. It is found that obvious flooding phenomena are observed after water addition both into the anode and cathode, which are alleviated during a constant-potential test at 0.6 V. Greater abilities of anti-flooding and mass transfer and higher current densities are found as the same amount of water is added at the anode. No diffusion loop is depicted in the impedance plots although a 58.3% flow volume is occupied by water. The maximum current density of 1.0 A cm-2 and the lowest Rct around 17 mΩ cm2 are obtained at the optimum state after 40 and 50 min of operation as 2.0 and 2.5 g of water are added, respectively. The porous metal pores store a certain amount of water to humidify the membrane and achieve an internal "self-humidification" function.

Large Deflection of Foam-Filled Triangular Tubes under Transverse Loading.

In this paper, the large deflection of the foam-filled triangular tube (FFTT) is studied analytically and numerically under transverse loading. Considering the strengths of the foam and the tube, the yield criterion of FFTT is established. Based on the yield criterion, a theoretical model for the large deflection of the clamped triangular tube filled with foam under transverse loading is developed. The numerical simulations are carried out using ABAQUS/Standard software, and the analytical results are compared with the numerical ones. The effects of foam strength, thickness of the tube, and the width of the punch on the load-bearing capacity and energy absorption of the clamped FFTT loaded transversally are discussed in detail. It is demonstrated that the load-bearing ability and the energy absorption increase with increasing foam strength, tube thickness, and punch width. The closer the loading position is to the clamped end, the greater the increases in the capacity of load bearing and the energy absorption of the triangular tube filled with foam. The theoretical model can be used to foresee the large deflection of metal FFTT under transverse loading.

Free Vibration Analysis of a Graphene-Platelet-Reinforced, Porous, Two-Cylindrical-Panel System.

In this study, a novel, dynamic model of a graphene-platelet-reinforced, porous (GPLRP) double-cylindrical-panel system is proposed. The material properties of a graphene-platelet-reinforced, porous, double-cylindrical-panel system were determined by the Halpin-Tsai micromechanics model and the typical mechanical properties of open-cell metal foams. Different types of porosity distribution and graphene platelet (GPL) distribution patterns were considered. Love's shell theory was utilized to derive the theoretical formulation, and the Rayleigh-Ritz method was used to calculate the natural frequencies of the system. The proposed model was validated by several comparison studies with the natural frequencies in the existing literature. Finally, the effects of stiffness of Winkler springs, boundary condition, porosity coefficient, porosity distribution, GPL distribution pattern, and GPL weight fraction on the free vibration characteristics of the system were evaluated.

New Aluminum Syntactic Foam: Synthesis and Mechanical Characterization.

Metal matrix syntactic foams (MMSF) are advanced cellular materials constituted by a system of a minimum of two phases, in which a dispersion of hollow particles is embedded by a continuous metal matrix. The incorporation of porous fillers favors the development of low-density materials with exceptional behavior for damping vibrations, impacts, and blast effects, shielding acoustic, thermal, and electromagnetic energies. There are three main techniques to produce them: infiltration casting technique (ICT), stir casting technique (SCT), and powder metallurgy technique (P/M). The first two techniques are used for embedding filler into lower melting point metallic matrices than fillers, in contrast to P/M. The present study demonstrates the feasibility of producing MMSF with components of similar melting points by ICT. The fillers were synthesized in-situ with aluminum and a natural foaming agent from wastes of Spanish white marble quarries. These novel aluminum syntactic foams (ASF) were mechanically characterized following the ISO-13314 and exhibited a porosity, plateau stress, and energy absorption capacity of 41%, 37.65 MPa, 8.62 MJ/m3 (at 35% of densification), respectively. These properties are slightly superior to equal porosity LECA ASF, making these novel ASF suitable for the same applications as LECA-ASF.

Improving the Melting Duration of a PV/PCM System Integrated with Different Metal Foam Configurations for Thermal Energy Management.

The melting duration in the photovoltaic/phase-change material (PV/PCM) system is a crucial parameter for thermal energy management such that its improvement can realize better energy management in respect to thermal storage capabilities, thermal conditions, and the lifespan of PV modules. An innovative and efficient technique for improving the melting duration is the inclusion of an exterior metal foam layer in the PV/PCM system. For detailed investigations of utilizing different metal foam configurations in terms of their convective heat transfer coefficients, the present paper proposes a newly developed mathematical model for the PV/PCM-metal foam assembly that can readily be implemented with a wide range of operating conditions. Both computational fluid dynamic (CFD) and experimental validations proved the good accuracy of the proposed model for further applications. The present research found that the average PV cell temperature can be reduced by about 12 °C with a corresponding improvement in PCM melting duration of 127%. The addition of the metal foam is more effective at low solar radiation, ambient temperatures far below the PCM solidus temperature, and high wind speeds in nonlinear extension. With increasing of tilt angle, the PCM melting duration is linearly decreased by an average value of (13.4-25.0)% when the metal foam convective heat transfer coefficient is changed in the range of (0.5-20) W/m2.K. The present research also shows that the PCM thickness has a positive linear effect on the PCM melting duration, however, modifying the metal foam configuration from 0.5 to 20 W/m2.K has an effect on the PCM melting duration in such a way that the average PCM melting duration is doubled. This confirms the effectiveness of the inclusion of metal foam in the PV/PCM system.

The Plastic Behavior in the Large Deflection Response of Fiber Metal Laminate Sandwich Beams under Transverse Loading.

The plastic behavior in the large deflection response of slender sandwich beams with fiber metal laminate (FML) face sheets and a metal foam core under transverse loading is studied. According to a modified rigid-perfectly plastic material approximation, an analytical model is developed, and simple formulae are obtained for the large deflection response of fully clamped FML sandwich beams, considering the interaction of bending and stretching. Finite element (FE) calculations are conducted, and analytical predictions capture numerical results reasonably in the plastic stage of large deflection. The influences of metal volume fraction, strength ratio of metal to composite layer, core strength, and punch size on the plastic behavior in the large deflection response of FML sandwich beams are discussed. It is suggested that, if the structural behavior of fiber-metal laminate sandwich beams is plasticity dominated, it is similar to that of metal sandwich beams. Moreover, both metal volume fraction and the strength ratio of metal to composite layer are found to be important for the plastic behavior in the large deflection response of fiber metal laminate sandwich beams, while core strength and punch size might have little influence on it.

Study on the effect of the size irregularity gradient of metal foams on macroscopic compressive properties.

Size irregularity gradient and cell wall gradient, combined as the density gradient in previous studies, affect the macroscopic mechanical properties of the gradient metal foam. More and more complex mesostructures are designed and applied in metal foams, and the density gradient becomes insufficient to describe the difference in mesostructures. To explore the effect of mesostructures carefully, this study focuses on the effect of the size irregularity gradient on the macroscopic compressive properties of metal foams. A series of metal foam models were developed using the 3D Voronoi technique. These models have the same average relative densities, the same average diameters and different size irregularity gradients. Simulation results indicated that the macroscopic mechanical properties of cell wall gradient metal foams are significantly different from those of size irregularity gradient metal foams, though these models have the same relative density gradient. To explore the effect of size irregularity gradient, a theoretical model was developed to characterize the compression process from the first cell-collapse to full condensation. Theoretical results showed a linear relationship between the nominal stress and the current relative density. These findings can provide efficient guidance for the design and applications of gradient metal foams.

Thermal Management for Hydrogen Charging and Discharging in a Screened Metal-Organic Framework Particle Tank.

Thermal management of H2 gas storage in a tank is crucial for determining the H2 gas deliverable capacity. In this study, a strategy for the design of an excellent comprehensive performance fuel storage tank from the screening of microscopic materials to the design of macroscopic particle adsorption tank performance is proposed. The best metal-organic framework (MOF) for H2 deliverable capacity in a computation-ready experimental MOF database is first screened using a grand canonical Monte Carlo (GCMC) method. An upscale model that combines the finite volume method with GCMC is then established to investigate the H2 charging and discharging processes in a screened best MOF-filled adsorption particle tank that is integrated with a phase-change material (PCM) jacket. The process of the heat and mass transfer in the screened best MOF particle adsorption tank with and without the PCM jacket-inserted metal foam is studied. The results show that the prescreened XAWVUN has the highest gravimetric and considerable volumetric deliverable capacity among 503 MOFs, which can reach up to 23.1 mol·kg-1 and 20.8 kg·m-3 at 298 K and pressures between 35 000 kPa (adsorption pressure) and 160 kPa (desorption pressure), respectively. The H2 deliverable capacity can be maximized by 3.2 and 12.1% for PCM jackets inserted with metal foam in the H2 charging and discharging processes when it is compared with the case without the PCM jacket, respectively. The above study will facilitate the development of new equipment for hydrogen storage.

Facile fabrication of binder-free photoelectrode for sensitive glucose sensing.

A novel carbon nitride particle-decorated three-dimensional porous nickel foam (CN/NF) was fabricated by a simple thermal polymerization deposition method for photoelectrochemical glucose detection. In this PEC sensing system, the synergetic effect of the photoactive CN and conductive current collector NF with multi-charge transfer channels contributed to the efficient separation of photoexcited charge carriers. The CN/NF electrode showed an excellent response for glucose detection and good anti-interference properties. A wide linear detection up to 1000µM and sensitivity of 460.2µA cm-2mM-1were obtained. This work provides a new strategy for designing binder-free electrodes for PEC sensing.

Effect of Metal Foam Insert Configurations on Flow Boiling Heat Transfer and Pressure Drop in a Rectangular Channel.

Heat transfer under flow boiling is better in a rectangular channel filled with open-cell metal foam than in an empty channel, but the high pressure drop is a drawback of the empty channel method. In this study, various types of metal foam insert configurations were tested to reduce the pressure drop while maintaining high heat transfer. Specifically, we measured the boiling heat transfer and pressure drop of a two-phase vertical upward flow of R245fa inside a channel. To measure the pressure and temperature differences of the metal foam, differential pressure transducers and T-type thermocouples were used at both ends of the test section. While the saturation pressure was kept constant at 5.9 bar, the steam quality at the inlet of the test section was changed from 0.05 to 0.99. The channel height, moreover, was 3 mm, and the mass flux ranged from 133 to 300 kg/m2s. The two-phase flow characteristics were observed through a high-speed visualization experiment. Heat transfer tended to increase with the mean vapor quality, and, as expected, the fully filled metal foam channel offered the highest thermal performance. The streamwise insert pattern model had the lowest heat transfer at a low mass flux. However, at a higher mass flux, the three different insert models presented almost the same heat transfer coefficients. We found that the streamwise pattern model had a very low pressure drop compared to that of the spanwise pattern models. The goodness factors of the flow area and the core volume of the streamwise patterned model were higher than those of the full-filled metal foam channel.

Highly Dissipative Materials for Damage Protection against Earthquake-Induced Structural Pounding.

It is a common situation that seismic excitations may lead to collisions between adjacent civil engineering structures. This phenomenon, called earthquake-induced structural pounding, may result in serious damage or even the total collapse of the colliding structures. Filling the gap between two buildings erected close to one another by using visco-elastic materials can be considered to be one of the most effective methods to avoid seismic pounding. In this paper, a new polymer-metal composite material made of polyurethane and closed-cell aluminum foam is proposed as a pounding energy absorber for protection against earthquake hazards. The composite was created in two versions, with and without an adhesive interface. A series of experiments which reflect the conditions of seismic collision were performed: quasi-static compression, dynamic uniaxial compression and low-cycle dynamic compression with 10 loops of unloading at 10% strain. The composite material's behavior was observed and compared with respect to uniform material specimens: polymer and metal foam. The experimental results showed that the maximum energy absorption efficiency in the case of the new material with the bonding layer was improved by 34% and 49% in quasi-static and dynamic conditions, respectively, in comparison to a sole polymer bumper. Furthermore, the newly proposed composites dissipated from 35% to 44% of the energy absorbed in the cyclic procedure, whereas the polymer specimen dissipated 25%. The capacity of the maintenance of the dissipative properties throughout the complete low-cycle loading was also satisfactory: it achieved an additional 100% to 300% of the energy dissipated in the first loading-unloading loop.

Time-Resolved PIV Measurements and Turbulence Characteristics of Flow Inside an Open-Cell Metal Foam.

Open-cell metal foams are porous medium for thermo-fluidic systems. However, their complex geometry makes it difficult to perform time-resolved (TR) measurements inside them. In this study, a TR particle image velocimetry (PIV) method is introduced for use inside open-cell metal foam structures. Stereolithography 3D printing methods and conventional post-processing methods cannot be applied to metal foam structures; therefore, PolyJet 3D printing and post-processing methods were employed to fabricate a transparent metal foam replica. The key to obtaining acceptable transparency in this method is the complete removal of the support material from the printing surfaces. The flow characteristics inside a 10-pore-per-inch (PPI) metal foam were analyzed in which porosity is 0.92 while laminar flow condition is applied to inlet. The flow inside the foam replica is randomly divided and combined by the interconnected pore network. Robust crosswise motion occurs inside foam with approximately 23% bulk speed. Strong influence on transverse motion by metal foam is evident. In addition, span-wise vorticity evolution is similar to the integral time length scale of the stream-wise center plane. The span-wise vorticity fluctuation through the foam arrangement is presented. It is believed that this turbulent characteristic is caused by the interaction of jets that have different flow directions inside the metal foam structure. The finite-time Lyapunov exponent method is employed to visualize the vortex ridges. Fluctuating attracting and repelling material lines are expected to enhance the heat and mass transfer. The results presented in this study could be useful for understanding the flow characteristics inside metal foams.