Structure and mechanical properties of ADC 12 Al foam–polymer interpenetrating phase composites with epoxy resin or silicone

Abstract

Abstract Metal foam is a high-porosity engineering material which has many outstanding properties such as lightness, high specific strength and stiffness, large energy absorption during impact and good thermal transportation. Impregnation of metal foams with polymers produces new types of composites such as interpenetrating phase composites (IPCs) and co-continuous composites, due to an interconnection on the macroscopic level of individual phases as a co-continuous 3-D network. The coexistence of the metal and polymer phases allows each to contribute its prominent properties to the composite. This novel composite material is a potential candidate for applications in the automotive and aerospace industries. The present study aims to develop two IPCs from open-cell Al foams of 20 ppi impregnated with silicone or epoxy resin. The compressive behavior and energy absorption characteristics of IPCs are also examined and compared. The results showed that although both IPCs have a similar foam structure with similar density, the disparities in the properties of impregnated polymers lead to distinct mechanical properties. The combination of the Al foam and polymers, both silicone and epoxy resin, yield stiffer IPCs than either of the two individual materials alone. Higher stiffness was found in IPCs with epoxy resin, owing to the brittle nature of the resin. Energy absorption capacity was also increased when compared with the original Al foam.