Analysis of Stainless Steel Sandwich Panels with a Metal Foam Core for Lightweight Fan Blade Design

Steel-steel composite metal foam (SS-CMF) and composite metal foam core sandwich panels (SS-CMF-CSP) were manufactured and tested under quasi-static tension. The SS-CMF-CSP were manufactured by attaching stainless steel face sheets to a SS-CMF core using solid-state diffusion bonding. SEM imaging was used to inspect the microstructure of SS-CMF and compare it to that of SS-CMF-CSP. The results indicate a cohesive bond line at the interface of the core and the face sheets. The bare SS-CMF samples had an ultimate tensile strength between 75–85 MPa and a failure strain between 7.5–8%. The normalized tensile strength of the SS-CMF was approximately 24 MPa/(g/cm3), 410% higher than other comparable metal foams, with a specific energy absorption of 0.95 J/g under tension. The uniform porosities and strong bonding between the sphere wall and matrix seem to be the strengthening factor of SS-CMF under tension when compared to other metal foams. The ultimate tensile strength of the SS-CMF-CSP was 115% stronger than the bare SS-CMF at 165 MPa with an average failure strain of 23%. The normalized strength of the SS-CMF-CSP was 52% higher than the bare SS-CMF. The modulus of elasticity was approximated using the rule of mixtures for the SS-CMF and the SS-CMF-CSP and the experimental results were found to lie within the calculated upper and lower bounds.

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Laser Forming of Metal Foam Sandwich Panels: Effect of Panel Manufacturing Method

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4043194 ◽

2019 ◽

Vol 141 (5) ◽

Cited By ~ 4

Author(s):

Tizian Bucher ◽

Min Zhang ◽

Chang Jun Chen ◽

Ravi Verma ◽

Wayne Li ◽

...

Keyword(s):

Metal Foam ◽

Numerical Models ◽

Sandwich Panels ◽

Weight Ratio ◽

Industrial Applications ◽

Laser Forming ◽

Process Conditions ◽

Foam Core ◽

Wide Range ◽

The Impact

Sandwich panels with metal foam cores have a tremendous potential in various industrial applications due to their outstanding strength-to-weight ratio, stiffness, and shock absorption capacity. A recent study paved the road toward a more economical implementation of sandwich panels, by showing that the material can be successfully bent up to large angles using laser forming. The study also developed a fundamental understanding of the underlying bending mechanisms and established accurate numerical models. In this study, these efforts were carried further, and the impact of the foam core structure, the facesheet and foam core compositions, and the adhesion method on the bending efficiency and the bending limit was investigated. These factors were studied individually and collectively by comparing two fundamentally different sandwich panel types. Thermally induced stresses at the facesheet/core interface were thoroughly considered. Numerical modeling was carried out under different levels of geometric accuracy to complement bending experiments under a wide range of process conditions. Interactions between panel properties and process conditions were demonstrated and discussed.

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The effect of morphological imperfections on damage in 3D FE analysis of open-cell metal foam core sandwich panels

International Journal of Mechanical Sciences ◽

10.1016/j.ijmecsci.2013.07.011 ◽

2013 ◽

Vol 75 ◽

pp. 377-387 ◽

Cited By ~ 2

Author(s):

Charles Betts ◽

Daniel Balint ◽

Jianguo Lin

Keyword(s):

Metal Foam ◽

Sandwich Panels ◽

Fe Analysis ◽

Foam Core ◽

Open Cell

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Analytical and numerical investigations on the penetration of rigid projectiles into the foam core sandwich panels with aluminum face-sheets

Proceedings of the Institution of Mechanical Engineers Part G Journal of Aerospace Engineering ◽

10.1177/0954410017730090 ◽

2017 ◽

Vol 233 (1) ◽

pp. 285-298

Author(s):

A Alavi Nia ◽

M Kazemi

Keyword(s):

Analytical Method ◽

High Speed ◽

Aluminum Foam ◽

Metal Foam ◽

Sandwich Panels ◽

Foam Core ◽

Polymer Foam ◽

High Speed Impact ◽

Mathematical Equations ◽

Density Ratios

The aim of this study was to evaluate the penetration of ballistic projectiles into the sandwich panels both analytically and numerically. Due to the complexity of the mathematical equations governing this phenomenon, very few analytical studies have been conducted in this area. Given the widespread use of sandwich panels consisting of metal face-sheets and metal foam core in aerospace industries, revisions are carried out on analytical method provided by Hoo Fatt et al. on polymer foam core and composite face-sheets sandwich panels. Then using the improved relations, the high speed impact of a cylindrical projectile on the sandwich panels with aluminum face-sheets and aluminum foam core with different density ratios has been discussed. Also, the penetration process is simulated and finally to evaluate the accuracy of the improved analytical method and simulations, the results are compared to the experimental data obtained from tests have been done on the panels with aluminum foam core and aluminum face-sheets. Results of the research show that the improved procedure and numerical simulations are in good agreement with the experiments.

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Investigating the Effect of Low Speed Impact on Sandwich Panel with Metal Foam Core (Comparing the Results of MATLAB and Abacus Analysis)

International Journal for Modern Trends in Science and Technology - RTT2020 ◽

10.46501/ijmtst060508 ◽

2020 ◽

Vol 6 (5) ◽

pp. 45-52

Author(s):

Hamed Farhadi Nai

Keyword(s):

Analytical Modeling ◽

Sandwich Panel ◽

Metal Foam ◽

Equations Of Motion ◽

Sandwich Panels ◽

Foam Core ◽

Spring Stiffness ◽

Mass Model ◽

Low Speed ◽

Three Samples

In this paper, analytical modeling and numerical simulation of sandwich panel behavior with metal foam core under low impact impact are presented and how the formation and development of impact defects in impact loading conditions in three samples with different face sizes Taken, checked. Multi-layer sandwich panels are made of epoxy carbon and the core is also made of metal foam. Analytical modeling of low speed shock load on sandwich panels, using mass model and two-degree free spring, has been used to calculate the contact force. The spring stiffness of the contact site, and the bending and shear spring stiffness of the sandwich panel are calculated, the values of which change over time. To solve the equations of motion, the exact solution method has been used and the radius of the affected area is calculated using energy equations. In the next section, simulation of low speed impact on sandwich panels with metal foam core is done in three samples of different sizes in Abacus software, so that we see how to create and develop defects in sandwich panels. In the next section, we have examined the results and compared the numerical solution and analytical simulation, which confirms the process of research and this has been proven to be important.

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Study on the Microstructure and Compression of Composite Metal Foam Core Sandwich Panels

Metallurgical and Materials Transactions A ◽

10.1007/s11661-020-05964-1 ◽

2020 ◽

Vol 51 (10) ◽

pp. 5187-5197 ◽

Cited By ~ 1

Author(s):

Jacob Marx ◽

Afsaneh Rabiei

Keyword(s):

Metal Foam ◽

Sandwich Panels ◽

Foam Core

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Laser Forming of Metal Foam Sandwich Panels: Effect of Panel Manufacturing Method

Volume 2: Processes; Materials ◽

10.1115/msec2019-2873 ◽

2019 ◽

Author(s):

Tizian Bucher ◽

Min Zhang ◽

Chang Jun Chen ◽

Ravi Verma ◽

Wayne Li ◽

...

Keyword(s):

Metal Foam ◽

Numerical Models ◽

Sandwich Panels ◽

Weight Ratio ◽

Industrial Applications ◽

Laser Forming ◽

Process Conditions ◽

Foam Core ◽

Wide Range ◽

The Impact

Abstract Sandwich panels with metal foam cores have a tremendous potential in various industrial applications due to their outstanding strength-to-weight ratio, stiffness, and shock absorption capacity. A recent study paved the road towards a more economical implementation of sandwich panels, by showing that the material can be successfully bent up to large angles using laser forming. The study also developed a fundamental understanding of the underlying bending mechanisms and established accurate numerical models. In this study, these efforts were carried further, and the impact of the foam core structure, the facesheet and foam core compositions, as well as the adhesion method on the bending efficiency and bending limit was investigated. These factors were studied individually and collectively by comparing two fundamentally different sandwich panel types. Thermally-induced stresses at the facesheet/core interface were thoroughly considered. Numerical modeling was carried out under different levels of geometric accuracy, to complement bending experiments under a wide range of process conditions. Interactions between panel properties and process conditions were demonstrated and discussed.

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