Effect of Core Density on the Three-Point Bending Performance of Aluminum Foam Sandwich Panels.

Using the powder-metallurgy rolling method, aluminum foam sandwich (AFS) panels with a metallurgical bond between the foam core and the panel can be produced. In this study, by manipulating the foaming temperature and duration, AFS panels were fabricated with varying core densities and thicknesses, all maintaining a panel thickness close to 1 mm. Through the three-point bending test, this research deeply delved into how core density influences the mechanical behaviors of these AFS panels. It became evident that a rise in core density positively affects the bending strength and failure load of the panels but inversely impacts their total energy absorption efficiency. Differing core densities brought about distinct failure patterns: low-density samples primarily showed panel indentation and core shear failures, whereas those of high density demonstrated panel yield and fractures. Furthermore, the research offers predictions on the initial failure loads for different failure modes and introduces a comprehensively designed failure diagram, laying a foundational theory for the production of AFS panels.

Aluminum Foam Sandwich: Pore Evolution Mechanism Investigation and Engineering Preparing Optimization.

This paper employs an innovative investigation approach to study pore evolution in Al-Si-Mg-Cu alloy within aluminum foam sandwiches (AFS) by integrating data from heating-expansion ratio curves, in situ observation of synchronous radiation, and microscopic analysis of the matrix's microstructure at different stages. Additionally, the cavity design and plate type control for large-scale AFS production are explored. Findings categorize the precursor heating into three stages: rapid heating, solid-liquid transition, and stable foaming. During solid-liquid transition, the expansion rate experiences a sudden drop, associated with pore nucleation and edge cracking of precursors. Pores nucleate as elongated crack-like structures along the rolling direction, guided by the Mg-enriched regions. In stable foaming, these pores evolve, become spherical, and the matrix rapidly expands. Using square tubes for sealing on the preform cavity sides creates a dense edge zone during rolling, halting crack propagation into the powder core. Adopting edge sealing during foaming mitigates boundary effects, thereby improving AFS panel flatness.

Investigation of the Indentation Resistance of Aluminum Foam Sandwich Panels with Metallurgical Bonding Interfaces under Low-Velocity Impact.

The impact resistance of aluminum foam sandwich panels (AFS) with metallurgical bonding interfaces prepared by the powder cladding rolling method was investigated. Low-velocity impact tests were conducted by using a drop-weight impact facility to explore the dynamic mechanical behavior, deformation and damage mechanisms, and energy absorption of AFS with metallurgical bonding interfaces. The effects of variation of impact energy, panel thickness, and specimen density on the energy absorption performance of AFS were quantitatively evaluated by energy absorption indicators. The results indicate that the load-displacement curve illustrates prominent three-stage characteristics when the impact energy is 120 J containing the front panel yielding stage, the foam core's compressive and shear failure stage, and the back panel fracture stage. The impact strength of the sandwich structure increases with increasing panel thickness and specimen density. The AFS with metallurgical bonding interfaces presents favorable energy absorption efficiency under low velocity.

Compressive Properties and Energy Absorption Behavior of 316L Steel Foam Prepared by Space Holder Technique.

The effect of porosity and pore size on the quasi-static compression properties and energy absorption characteristics of the steel foam was investigated in this paper. The 316L steel foams were prepared through powder metallurgy using urea as the space holder. The macrostructure of steel foam and microstructure of the pore walls were characterized, and the quasi-static compression experiments were conducted on the specimens in the axial direction at a strain rate of 10-3 s-1. The results show that the increase in porosity decreases the yield strength and plastic modulus of the steel foam but increases the densification strain of the steel foam. The yield strength of the steel foam decreases significantly when the pore size is 2.37 mm. However, the pore size has little effect on the plastic modulus. Moreover, the energy absorption per volume of the steel foam decreases with increasing porosity at the same strain. The effect of porosity on energy absorption efficiency is greater than that of pore size.

Fatigue of an Aluminum Foam Sandwich Formed by Powder Metallurgy.

In this paper, an aluminum foam sandwich (AFS) was prepared by the rolling composite-powder metallurgy method, and its fatigue properties were studied. It was compared with an AFS made by the adhesive method to study its fatigue properties more directly. In this experiment, the fatigue performance was investigated by studying the microscopic interface, fatigue life, deflection curve, and failure mode. The results show that the fatigue life of an AFS with the rolling composite-powder metallurgy method is much longer than that with the adhesive method. The failure mode of an AFS made by the rolling composite-powder metallurgy method is shear failure, and that of an AFS made by the adhesive method is shear failure and interface debonding. An AFS with the rolling composite-powder metallurgy method has better fatigue properties. This paper also explored the fatigue damage model using the fatigue modulus method, and the polynomial fitting method has a higher fitting degree.

Effect of Deep Cryogenic Time on Martensite Multi-Level Microstructures and Mechanical Properties in AISI M35 High-Speed Steel.

High-speed steel is widely used for cutting tools due to its convenience of preparation and cost-effectiveness. Previous research has shown that deep cryogenic treatments improve the mechanical properties of high-speed steel, due to the transformation of the residual austenite and the precipitation of carbide, while few studies have researched martensitic changes. The variations in martensite multi-level microstructures in AISI M35 high-speed steel, treated over different deep cryogenic time periods, were investigated in this study. Meanwhile, the effect of these variations on the mechanical properties of the selected steel was discussed. It was found that prolonging deep cryogenic time facilitated an increase in dislocation, low-angle grain boundary, and the coincident-site lattice boundary (especially the twin boundary) of martensite. The size of the martensite block (db) and lath (dl) decreased with deep cryogenic time. However, the effect on the microstructure was limited when the cryogenic treatment time exceeded 5 h. The increase in dislocation decreased the temperature for carbide precipitation and promoted fine carbide precipitation during tempering. The refinement of martensite multi-level microstructures and the greater precipitation of fine carbides gave the tempered specimens excellent impact toughness. The impact toughness of the tempered samples undergoing deep cryogenic treatment for more than 5 h was about 32% higher than the sample without deep cryogenic treatment.

Three-Point Bending Behavior of Aluminum Foam Sandwich with Different Interface Bonding Methods.

The interface bonding method has a great influence on the mechanical properties of aluminum foam sandwich (AFS). This study aims to investigate the effect of different interface bonding methods on the mechanical properties of AFS. In this paper, the metallurgical-bonding interface-formation mechanism of AFS prepared by powder metallurgy was investigated. The shear properties of metallurgical-bonded AFS were determined by the panel peeling test. The flexural properties and energy absorption of metallurgical-bonded and glued AFS were analyzed through the three-point bending test. The results show that the magnesium, silicon, and copper elements of the core layer diffuse to panels and form a metallurgical composite layer. The metallurgical-bonding strength between the panel and core layer is higher than that of the foam core layer. The peak load of metallurgically-bonded AFS is 24% more than that of glued AFS, and energy absorption is 12.2 times higher than that of glued AFS.

Densification Mechanism for the Precursor of AFS under Different Rolling Temperatures.

The effect of rolling temperature on the precursor of aluminum foam sandwich (AFS) prepared by powder metallurgy through Pack Rolling method is investigated in this work. The cross-section along rolling direction of the precursors was observed. It was found that periodic corrugated morphology with micro-cracks on the composite interface as well as cracks and micro-holes among core powder particles emerged abundantly at room temperature rolling. These defects degraded with increasing rolling temperature and completely disappeared when the rolling temperature reached 400 °C. Combining with foaming ability of these precursors, the densification mechanism of core powders was discussed. Powder particles deformed with difficulty at low rolling temperature; the gap between them cannot be effectively filled through their plastic deformation. Fracture occurred in powder core layer during co-extension with the outer panel and was partly embedded by it, resulting in corrugated composite morphology at the interface. The precursors of high density and excellent bonding interface were prepared at the rolling temperature of 400 °C. A more suitable foaming condition was determined.