Mechanism Elucidation of High-Pressure Generation in Cellular Metal at High-Velocity Impact

Cellular metals exhibit diverse properties, depending on their geometries and base materials. This study investigated the mechanism of high-pressure generation during the high-velocity impact of unidirectional cellular (UniPore) materials. Cubic UniPore copper samples were mounted on a projectile and subjected to impact loading using a powder gun to induce direct impact of samples. The specimens exhibited a unique phenomenon of high-pressure generation near the pores during compression. We elucidate the mechanism of the high-pressure phenomenon and discuss the pore geometries that contribute to the generation of high pressures.

Cellular Metals: Fabrication, Properties and Applications

Cellular solids and porous metals have become some of the most promising lightweight multifunctional materials due to their superior combination of advanced properties mainly derived from their base material and cellular structure [...]

Brief Review on Experimental and Computational Techniques for Characterization of Cellular Metals

The paper presents a brief review of the main experimental and numerical techniques and standards to investigate and quantify the structural, mechanical, thermal, and acoustic properties of cellular metals. The potential of non-destructive techniques, such as X-ray computed tomography and infrared thermography are also presented.

2D Finite Element Modeling of the Cutting Force in Peripheral Milling of Cellular Metals

The machining of cellular metals has been a challenge, as the resulting surface is extremely irregular, with torn off or smeared material, poor accuracy, and subsurface damage. Although cutting experiments have been carried out on cellular materials to study the influence of cutting parameters, current analytical and experimental techniques are not suitable for the analysis of heterogeneous materials. On the other hand, the finite element (FE) method has been proven a useful resource in the analysis of heterogeneous materials, such as cellular materials, metal foams, and composites. In this study, a two-dimensional finite element model of peripheral milling for cellular metals is presented. The model considers the kinematics of peripheral milling, depicting the advance of the tool into the workpiece and the interaction between the cutting edge and the mesostructure. The model is able to simulate chip separation as well as the surface and subsurface damage on the machined surface. Although the calculated average cutting force is not accurate, the model provides a reasonable estimation of maximum cutting force. The influences of mesostructure on cutting processes are highlighted and the effects in peripheral milling of cellular materials are discussed.

Structural Loading of Cellular Metals: Damage Mechanisms and Standardization Concepts

Structural loading of cellular metals is strongly affected by brittle fracture of cell struts and walls that exhibit tensile loads, e.g., during fatigue loading. The present paper summarizes results of compression, tension and cyclic loading experiments on various closed-cell metal foams and metal foam sandwiches (Alulight, Alporas, Foamtech, AFS) using various mechanical testing systems. The results were correlated with a thorough analysis of the cellular mesostructure and the cell strut/wall microstructure by means of scanning electron microscopy revealing defects, such as casting porosity and large Si precipitates in the Al-Si eutectic of aluminum cast alloy. The results of the work served for the definition of testing standards for compression testing (ISO 13314) and tensile testing (DIN 50099), which are outlined in the paper. Such standards and design guidelines are crucial for a successful implementation of cellular metals in innovative products in mechanical, automotive and energy engineering as well as in bioengineering.