Formability of Open-Cell Aluminum Foams by Laser

2010 ◽  
Author(s):  
Loredana Santo ◽  
Alessandro Guglielmotti ◽  
Fabrizio Quadrini
Keyword(s):  
Element Model ◽  
Laser Forming ◽  
Process Conditions ◽  
Al Alloy ◽  
Aluminum Foams ◽  
Bending Tests ◽  
Open Cell ◽  
Laser Velocity ◽  
Material Interaction ◽  
Al Foams

A new forming method for open-cell aluminum (Al) foams by laser was introduced. Laser forming is generally applied to sheet metals but a good formability was observed also for Al alloy cellular structures. In this study, laser bending tests were performed on rectangular samples made of open-cell Al alloy foams by means of a diode laser. Laser scan velocity and power were changed in the experimentation so as to identify the best process conditions for three different Al foams. A finite element model was implemented to simulate the laser-material interaction during forming in dependence of the foam structure. At fixed values of laser velocity and power, higher bending angles were obtained for foams with smaller pores but, changing the process parameters, a better formability was observed for the foams with bigger pores.

Numerical Simulation of Open-Cell Aluminum Foams under Compression

2012 ◽  
Vol 504-506 ◽  
pp. 1219-1224 ◽  
Author(s):  
Fabrizio Quadrini ◽  
Denise Bellisario ◽  
Daniele Ferrari ◽  
Loredana Santo
Keyword(s):  
Numerical Simulation ◽  
Base Material ◽  
Element Model ◽  
Laser Forming ◽  
Compression Tests ◽  
Aluminum Foams ◽  
Compression Behavior ◽  
Open Cell ◽  
Forming Simulation ◽  
Alloy Base

The numerical simulation of the compression behavior of open-cell aluminum foams is discussed as a way to extract material property information for laser forming simulation. A bilinear isotropic model was implemented for the alloy base material whereas a parametric approach was used to build the finite element model of the foam structure. Compression tests were performed on commercial foams with different pore size and density, and the results of lower density foam were used for the model validation. Numerical results show a good agreement with experimental data in terms of foam deformation under compression and required loads.

scholarly journals Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1715
Author(s):  
Sara Ferraris ◽  
Antonio Santostefano ◽  
Antonio Barbato ◽  
Roberto Molina ◽  
Graziano Ubertalli
Keyword(s):  
Skin Thickness ◽  
Al Alloy ◽  
Strength Increase ◽  
Aluminum Foams ◽  
Gravity Casting ◽  
Acoustic Insulation ◽  
Metallurgical Bonding ◽  
Compression Resistance ◽  
Effect Of Surface ◽  
Al Foams

An emerging and still poorly explored application of aluminum foams is their potential use as permanent cores (inserts) in the casting of aluminum alloys. In this context, Al-based foams can introduce a weight reduction, the obtainment of cavities, a strength increase, the ability to absorb impact energy and vibration, acoustic insulation ability, the possibility to simplify the technological processes (no removal/recycling of traditional sand cores), and finally, they can be fully recyclable. Cymat-type Al foams with thin outer skin were used as permanent cores in Al-alloy gravity casting in the present research. Al-foams were characterized in terms of porosity, density, cell wall and skin thickness, surface chemical composition and morphology, and compression resistance. Cast objects with foam inserts were characterized by means of optical microscopy. The preservation of up to 50% of the initial porosity was observed for foam inserts with higher density. Metallurgical bonding between the foam core and the cast metal was observed in some regions.

Microstructural Modification of Laser-Bent Open-Cell Aluminum Foams

2012 ◽  
Vol 504-506 ◽  
pp. 1213-1218 ◽  
Author(s):  
Loredana Santo ◽  
Denise Bellisario ◽  
Ludovica Rovatti ◽  
Fabrizio Quadrini
Keyword(s):  
Laser Heating ◽  
Laser Power ◽  
Laser Forming ◽  
Processing Conditions ◽  
Aluminum Foams ◽  
Laser Bending ◽  
Bending Angle ◽  
Open Cell ◽  
Scan Rate ◽  
Alloy Microstructure

Laser forming tests have been performed on open-cell aluminum alloy foams with different pore size. Laser power was fixed at 150 W, a total of 150 laser scans led to a bending angle up to 60°, depending on the laser scan rate. At the end of the laser bending, the foams were left to cool and samples were extracted for analysis by means of an optic microscope. The alloy microstructure was investigated in different points of the samples and correlated with the processing conditions. Image analysis was also carried out to extract the percentage of melted area due to laser heating.

Investigation of AC8A Scrap-Recycled Aluminum Foams

2014 ◽  
Vol 894 ◽  
pp. 134-137
Author(s):  
Seksak Asavavisithchai ◽  
Natthida Jareankieathbovorn ◽  
Areeya Srichaiyaperk
Keyword(s):  
Casting Process ◽  
Polyurethane Foams ◽  
Aluminum Foams ◽  
Major Drawback ◽  
Pressure Infiltration ◽  
Open Cell ◽  
Al Foam ◽  
The Cost ◽  
Recycled Material ◽  
Al Foams

Open-cell Al foam has outstanding properties which are suitable for functional applications. However, a major drawback for widespread employment of Al foam is its high relative cost which can be several times higher than conventional metals. To reduce the cost, a recycled material waste is constructively used instead of expensive base metal. The present study aims to fabricate economical open-cell Al foams using AC8A alloy scrap from lathe machines. The Al foams were fabricated through pressure infiltration casting process at which the cellular pattern was made from commercial reticulated open-cell polyurethane foams with the pore size of 12 ppi. The compressive strength and microhardness of scrap-recycled Al foams are higher than those of pure Al foam. The increase in foam mechanical properties resulted from the change in foam microstructure as the formation of Si hard phase in Al matrix. The strength and microhardness of the foams increase with increasing scrap contents.

Numerical Simulation of Laser Bending of Aluminum Foams

2013 ◽  
Vol 554-557 ◽  
pp. 1864-1871 ◽  
Author(s):  
Fabrizio Quadrini ◽  
Denise Bellisario ◽  
Daniele Ferrari ◽  
Loredana Santo ◽  
Anna Santarsiero
Keyword(s):  
Element Model ◽  
Mechanical Tests ◽  
Material Behavior ◽  
Laser Forming ◽  
Main Process ◽  
Process Variables ◽  
Aluminum Foams ◽  
Laser Bending ◽  
Final Model ◽  
Closed Cell

Laser forming of open-cell aluminum foams has been modeled by means of a 3D finite element model which is able to take into account the real foam geometry as well as the main process variables. A parametric procedure has been defined for the geometry construction and meshing, and the simulation run. In order to calibrate and validate numerical modeling, compression and flexure tests were performed on a closed-cell aluminum foam. The simulation of mechanical tests allowed a correct modeling of the aluminum alloy behavior under plastic deformation. The same material behavior was implemented in a complex thermo-mechanical model for laser bending simulation. The final model is able to predict the shape evolution during forming and the correlation between process variables and final bent angles.

scholarly journals Thermo-mechanical analysis of linear welding stage in friction stir welding - influence of welding parameters

2021 ◽  
pp. 186-186
Author(s):  
Darko Veljic ◽  
Marko Rakin ◽  
Aleksandar Sedmak ◽  
Nenad Radovic ◽  
Bojan Medjo ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Welding Speed ◽  
Reaction Force ◽  
Material Model ◽  
Element Model ◽  
Welding Parameters ◽  
Al Alloy ◽  
Friction Stir ◽  
Fsw Parameters

The influence of friction stir welding (FSW) parameters on thermo-mechanical behaviour of the material during welding is analysed. An aluminium alloy is considered (Al 2024 T351), and different rotating speed and welding speed are applied. Finite element model consists of the plate (Al alloy), backing plate and welding tool, and it is formed and solved in software package Simulia Abaqus. The influence of the welding conditions on material behaviour is taken into account by application of the Johnson-Cook material model. The rotation of the tool affects the results: if increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, the plastic deformation of the material, is negligibly changed. When the welding speed is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming increases. Combined, these two effects cause small change of the total heat generation. For the same welded joint length, the plate welded by lower speed will be heated more intensively. The changes of the heat generation influence both the temperature field and reaction force, which are also considered.

A novel method for making open cell aluminum foams by powder sintering process

2005 ◽  
Vol 59 (26) ◽  
pp. 3333-3336 ◽  
Author(s):  
B. Jiang ◽  
N.Q. Zhao ◽  
C.S. Shi ◽  
X.W. Du ◽  
J.J Li ◽  
...  
Keyword(s):  
Sintering Process ◽  
Aluminum Foams ◽  
Open Cell ◽  
Powder Sintering ◽  
Novel Method

The Effects of Compression and Pore Size Variations on the Liquid Flow Characteristics in Metal Foams

2001 ◽  
Vol 124 (1) ◽  
pp. 263-272 ◽  
Author(s):  
K. Boomsma ◽  
D. Poulikakos
Keyword(s):  
Flow Characteristics ◽  
Maximum Flow ◽  
Metal Foams ◽  
Heat Sinks ◽  
Convection Heat ◽  
Hydraulic Characteristics ◽  
Aluminum Foams ◽  
Transitional Regime ◽  
Open Cell ◽  
Flow Velocities

Open-cell aluminum foams were investigated using water to determine their hydraulic characteristics. Maximum fluid flow velocities achieved were 1.042 m/s. The permeability and form coefficient varied from 2.46×10−10 m2 and 8701 m−1 to 3529×10−10 m2 and 120 m−1, respectively. It was determined that the flowrate range influenced these calculated parameters, especially in the transitional regime where the permeability based Reynolds number varied between unity and 26.5. Beyond the transition regime where ReK≳30, the permeability and form coefficient monotonically approached values which were reported as being calculated at the maximum flow velocities attained. The results obtained in this study are relevant to engineering applications employing metal foams ranging from convection heat sinks to filters and flow straightening devices.

Effect of Heat Treatment on Compressive Properties of Open Cell Aluminum Foams

2007 ◽  
pp. 1417-1420
Author(s):  
Chen Li ◽  
Zhi Hua Wang ◽  
Hong Wei Ma ◽  
Long Mao Zhao ◽  
Gui Tong Yang
Keyword(s):  
Heat Treatment ◽  
Compressive Properties ◽  
Aluminum Foams ◽  
Open Cell
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