Open-cell Aluminum Foam Research Articles

Experimental Investigation and Calculation of Convective Heat Transfer in Two-Component Gas–Liquid Flow Through Channels Packed with Metal Foams

This paper presents a study on heat transfer in two-phase mixtures (air–water and air–oil) flowing through heated horizontal channels filled with open-cell aluminum foams characterized by porosities of 92.9–94.3% and pore densities of 20, 30, and 40 PPI. The research included mass flux densities ranging from 2.82 to 284.7 kg/(m2·s) and heat flux densities from 5.3 to 35.7 kW/m2. The analysis examined the effects of flow conditions, fluid properties, and foam geometry on the intensity of heat transfer from the heated walls of the channel to the fluid. Results indicate that the heat transfer coefficient in two-component non-boiling flow exceeds that of single-phase flow, primarily due to fluid properties and velocities, with minimal impact from flow structures or foam geometry. An assessment of existing methods for predicting heat transfer coefficients in gas–liquid and boiling flows revealed significant discrepancies—up to several hundred percent—between measured and predicted values. To address these issues, a novel computational method was developed to accurately predict heat transfer coefficients for two-component non-boiling flow through metal foams.

Manufacturing and characterization of open-cell aluminum foam by powder metallurgy

Manufacturing and characterization of open-cell aluminum foam by powder metallurgy

The structural and mechanical properties of open-cell aluminum foams: Dependency on porosity, pore size, and ceramic particle addition

Aluminum foams are desired for lightweight, high-performance, and cost-effective materials, particularly in automotive, aerospace, and advanced power plants. Expansion of their applications depends on developing a detailed understanding of the structural and mechanical properties of aluminum foams. In this research, open-cell aluminum foams with 25.51–81.88 % porosity were manufactured through powder metallurgy using a space holder technique, with varying carbamide (urea) ratios (17–80 %) and particle sizes (1–1.4 mm, 1.7–2 mm, 2–2.4 mm). Three different ceramic particles, B4C, Al2O3, and SiC were used as reinforcement to improve the compression properties and energy absorption capacity of the foam materials. The study determined open and closed porosity ratios, spherical diameter, sphericity values, micropore sizes, mechanical properties, and energy absorption capacity of the foam samples both with and without ceramic additives. The results show that porosity ratio, pore size, and ceramic particle addition significantly affect aluminum foams' structural and mechanical properties, allowing for tailored properties for specific applications. It was observed that as porosity increased, compressive stress decreased, and the length of the plateau region and the shape change where densification began increased. However, there was no significant change in compressive stress and specific energy values with changing pore size. The optimal B4C addition was found to be 4 %, which significantly improved compressive strength to 3.75 MPa and specific energy to 4.24 MJ m−3.

Mechanical Properties and Deformation Behavior of Open-Cell Type Aluminum Foams with Structural Conditions and Alloy Composition

Open-cell type aluminum foams with various structural conditions and alloy compositions were manufactured using the replication casting process. The porosity of the foams ranged from 55% to 62%, with pore sizes of 0.7~1.0 mm, 1.0~2.0 mm, and 2.8~3.4 mm. The alloys employed included commercial A356 and A383, as well as Al-6Mg-(0, 2, 4, 6)Si alloys. Compression tests were conducted under various conditions of the foams, and the results were comparatively analyzed based on the detailed structural conditions and alloy compositions. It was observed that for the same alloy composition and equivalent porosity, a reduction in pore size led to an increased number of cell walls, enhancing energy dispersion and resulting in higher compressive yield strength and energy absorption. Under the same pore size, a decrease in porosity increased the relative density and cell wall thickness, leading to improved compressive yield strength and energy absorption. Furthermore, compressive evaluation based on alloy composition revealed the influence of the inherent mechanical properties of the material on the mechanical properties of open-cell type aluminum foams. Specifically, it was confirmed that alloys with higher ductility exhibited elastic behavior of the internal cells under external stress, significantly influencing the energy absorption of foams.

Modification of open-cell cast aluminum-silicon foams with strontium

The mechanical properties of open-cell aluminum foams can be influenced by enhancing the microstructure of the struts. The foams produced by investment casting face slow cooling rates, which makes it challenging to improve the morphology of the phases. In the case of aluminum silicon cast foams, the silicon phase accumulates on the surface of the struts, which leads to brittle fractures. In the present study, we successfully modified the silicon phase in open-cell AlSi7Mg and AlSi10Mg cast foams by adding strontium and investigated the influence of the strontium content on the microstructure and mechanical properties at the foam and strut levels. Despite the cooling rates of less than 0.5 °C/s during solidification, the strontium addition of 200–800 ppm effectively decreased the size of the silicon particles and improved their distribution in the micrometer-sized struts. Improvements in the compressive properties of the foams and the tensile properties of the struts only occurred at the strontium levels of 200 and 400 ppm. The effective modification in this casting condition is due to the limited solidification space, which favors the formation of the atomic clusters responsible for the modification.

On the Efficiency of Air-Cooled Metal Foam Heat Exchangers

This study analyses the heat transfer performance of metal foam heat exchangers through experimental measurements. Using counter-gravity infiltration casting, open-cell aluminium foam elements were manufactured to embed a copper tube for internal mass flow containment. Heat transfer experiments were conducted under natural and forced convection conditions, with the airflow controlled in a wind tunnel. A stream of warm water within the internal foam component served as the heat source, transferring thermal energy to the surrounding air flowing through the external foam component of the heat exchanger. The results showed a significantly enhanced heat transfer performance with aluminium foam compared to a single copper tube. Thermal resistance models were developed to elucidate the heat transfer mechanisms, highlighting the effectiveness of air-cooled metal foam heat exchangers. These findings underscore the potential of metal foam heat exchangers as cost-effective alternatives for various thermal management applications.

Pressure propagation mechanism of open-cell aluminium foam within a pipe under hypervelocity impact

Low-density open-cell aluminium (Al) foam exhibits a different deformation mode under hypervelocity impacts compared to being subjected to medium-low speed and quasi-static compression. In this case, material flows between cells in the form of metal jets and propagates forward. This paper establishes the open-cell Al foam model based on Voronoi tessellation. Using numerical methods, one-dimensional hypervelocity constant velocity impact experiments of 1–6 km/s inside a closed pipe are conducted on Al foam with different internal structure parameters (average cell diameter: 2–3.5 mm; ligament width: 0.251–1 mm). Propagation mechanism of pressure waves in foams and the key factors affecting the propagation velocity are investigated. Three zones are divided according to the condition of jet distribution along the impact direction: unaffected zone, jet influence zone, and particle accumulation zone. The variation of the length of different zones with impact velocity is discussed: higher velocities result in longer jet influence zones but shorter particle accumulation zones. Meanwhile, length of zones is closely related to the width of Al foam ligament and cell pore diameter: the larger the diameter of cell pores and the smaller the width of ligaments, the longer the length of the jet influence zone. Time dependence is exhibited in the length of jet influence zone for the large cell pore diameter specimens(≥0.03 cm). Particle pressures are extracted using the one-dimensional averaging method, which propagates forward significantly lower than in dense materials. Dominant factors affecting the pressure wave propagation of open-cell Al foam, i.e., the internal unloading space, are obtained by combining two-dimensional hypervelocity impact simulation experiments with different boundary conditions. A strong correlation between metal jet distribution and particle pressure propagation is observed.

Sound absorption performance and mechanism of aluminum foam with double-layer structures of conventional and porous cell walls

Open-cell aluminum foam exhibits sound absorption valleys in the 2500-4000 Hz range, reducing its sound absorption performance in the 800–6300 Hz range. This paper prepared a novel aluminum foam with a double-layer structure using the infiltration casting method, and its pore structure, sound absorption performance, acoustic model, and sound absorption mechanism are investigated. The double-layer structure consists of a conventional pore (CP) layer with a single pore size of 250 μm or 600 μm and a porous cell wall (PCW) layer with double pore diameters of 250 μm and 600 μm. As the thickness ratio between the CP and PCW layers decreases, the acoustic absorption valley value of the double-layer structure increases when combined with a small-pore CP layer. In contrast, it decreases slightly when combined with a large-pores CP layer. The double-layer structure reaches a sound absorption valley value and average sound absorption coefficient of 0.912 and 0.902, respectively. The double-layer structure's sound absorption valley value is better than that of a homogeneous structure, improving sound absorption performance. A Lu modified model is established to characterize the sound absorption of the double-layer structure, which closely matches the experimental results. The modified model further analyzed the vital geometrical parameters affecting the absorption valleys. Acoustic impedance analysis shows the enhanced sound absorption valleys are due to: 1) Gradient acoustic impedance reduces sound reflections at the air-structure interfaces and increases secondary reflection at the interfaces in the structure; 2) The series–parallel configuration increased the resonance peak bandwidth, while the dual-sized resonance cavities regulated the resonance peak frequency.

Study on sound absorption valley and acoustic absorption performance of small-pore aluminum foam composited with 304 stainless steel fibers

Open-cell aluminum foam exhibits a sound absorption valley (SAV) in the 2500–4000 Hz frequency range, reducing its acoustic absorption in the range of 1000–6300 Hz. A small-pore aluminum foam composited with 304 stainless steel fibers (SP-SS304F aluminum foam) with a porosity of 82 % was fabricated via infiltration casting, and its pore structure, acoustic absorption performance, and mechanism were investigated. The pore structure of SP-SS304F aluminum foam consisted of 223–676 μm main pores, 125–373 μm cell wall pores, and 30–60 μm 304 stainless steel fibers. The fibers existed completely embedded in the cell walls, partially or completely embedded in the cell cavities. As the pore diameter decreases, the SAV value increases and then decreases. With increasing fiber content, the SAV value showed a similar trend. The increased SAV value benefits the enhancement of the average sound absorption coefficient (SAC). The SP-SS304F foam aluminum reaches an optimal SAC value of 0.899. Its static resistivity value is 24,345 Pa.s/m2. Finite element simulations reveal the reasons for the improved acoustic absorption performance of SP-SS304F aluminum foam: First, the small-diameter and pore-embedded fibers improve the acoustic impedance matching, reducing sound reflections at the SAV frequency. Second, the reduced pore diameters and partially or completely pore-embedded fibers increase the pore surface areas, intensifying the acoustic absorption by pore structure.

Preparation and Compression Behavior of High Porosity, Microporous Open-Cell Al Foam Using Supergravity Infiltration Method.

By employing a method that combines a NaCl compacting template and supergravity infiltration, open-cell aluminum (Al) foam with varying porosities was prepared. The Al foam fabricated has a pore size of 400 µm and porosity ranging from 0.72 to 0.88. The experimental results indicate that, with an increase in compaction pressure during the NaCl compacting process, the porosity of the foam Al increases and the struts become finer. As the gravity coefficient increases, the density and integrity of the foam Al also increase. Due to the effectiveness of supergravity in overcoming the infiltration resistance between the NaCl preform and molten Al, the supergravity infiltration method holds promise as a practical new technique for fabricating high-porosity open-cell Al foam.

Experimental study of the low-velocity impact behavior of open-cell aluminum foam made by the infiltration method

This study examined the behavior and energy absorption of open-cell aluminum foam under different loading conditions. The foam was made by infiltration, a low-cost method that produced a uniform pore distribution. The foam was compressed using two machines with varying impact velocities and weights. The stress–strain and energy absorption curves of the foam were measured and analyzed. The results showed that the strain rate and the impact weight affected the compressive properties and energy absorption of the foam. The strain rate up to 264 s−1 with constant mass did not affect the plateau stress, which was the constant stress in the plastic region. However, at 264 s−1, increasing the impact weight increased the plateau stress and the energy absorption of the foam, which showed that the strain rate sensitivity depended on the impact inertia. The study revealed the dynamic characteristics of open-cell aluminum foam made by infiltration and provided insights for its use in impact protection. The study also showed that infiltration was a reliable and consistent method for making open-cell aluminum foam. The study highlighted the important roles of plateau stress and hardening effect in influencing the energy absorption of the foam under dynamic loading. The study suggested that future studies should consider the impact inertia as a parameter that affects the strain rate sensitivity of the foam.

Manufacturing Method and Thermal Properties of Open-Cell Type Aluminum Foam by Replication Casting Process

Open-cell type aluminum foam possesses unique structural characteristics comprising numerous interconnected pores within. This intriguing structure facilitates the passage of fluids (gas or liquid) through the interior of the open-cell type aluminum foams, enabling easy transfer to the exterior. The objective of this study is to manufacture open-cell type aluminum foams with varying pore sizes using the replication casting process and to evaluate their thermal properties. The equipment designed for the production of open-cell type aluminum foams consists of a chamber and an inner container. The chamber is connected to a vacuum line and an Ar gas line, with the container positioned inside. The aluminum alloys utilized for the foams were A356 and ADC12, and Na2CO3 served as the space holder. As a result of manufacturing the foams, there was no significant difference of porosity with space holder size and alloy types, the porosity averaged around 62%. To investigate the thermal properties of open-cell type aluminum foams in relation to pore size and alloy types, temperature variations were measured during sample heating via the hot plate method. Consequently, it was confirmed that the thermal properties of the foams were influenced by the structural conditions and alloy types.

Experimental study about the impact of open cell aluminium foam (OCAF) insertion in salt-based phase change material (PCM) for electronics thermal management

Thermal management of electronic components is a critical task in a harsh thermal environment. Spacecraft and satellites' electronics are susceptible to highly intermittent heating and cooling thermal conditions, which imposes challenges for robust thermal management system design. Phase change materials (PCM) are a promising solution for overcoming these challenges and enhancing thermal control performance. The lower PCM thermal conductivity and PCM supercooling limit PCM utilisation in electronic thermal control systems. The present study aims to provide solutions for enhancing the heat transfer within the PCM, boosting the PCM thermal conductivity, and diminishing the PCM supercooling. The open-cell aluminium foam (OCAF) was adopted for boosting the heat transfer within the PCM. A thermal management module (TMM) integrated with a salt-based PCM/OCAF composite was developed for electronics thermal management. The TMM was tested under intermittent thermal conditions of heating and cooling. An electric heater and Peltier cooler were affixed to the TMM for the heating and cooling process, respectively. Three levels of heat fluxes were adopted: 700, 1000, and 1400 W/m2. The heating process lasted one hour; then, the TMM was cooled by the Peltier element to the initial temperature. The research novelty covers the gap in understanding how OCAF affects salt-based PCM supercooling when subjected to varying heating loads during intermittent cycles. The outcomes reported a remarkable improvement in thermal management efficiency. The PCM-based TMM reduced the highest temperature by about 20.4 %, 21.6 %, and 23 % at the three heating levels. The OCAF diminished the PCM supercooling curiously. The reduction in PCM supercooling was 43.5 % compared to the 100 % PCM case obtained at the heat flux of 1400 W/m2.

Overall elastic characterization of equivalent FE models for aluminum foams through computational homogenization approach and genetic algorithm optimization

Aluminum foams are gaining increasing interest because of their widespread set of functional attributes combined with highly specific structural properties and affordable manufacturing processes. The finite element analysis of foam materials is typically performed with complex and time-consuming 3D models. Here, a beam FE model strategy is utilized to obtain a precise and time-saving simulation instrument for open-cell aluminum foams. The beam FE modeling is based on the Kelvin cell as a fundamental unit and provides a simplified geometrical description of the intersection node between ligaments whose elastic properties need to be adjusted through a calibration procedure. The beam FE model elastic properties are measured through a homogenization procedure that evaluates the elastic constants of an equivalent material. The issue of model calibration is formulated as an optimization problem exploiting the NSGA-II genetic algorithm. This procedure allows obtaining the full elastic calibration of the beam FE model, reproducing the orthotropic elastic behavior of the aluminum foams with reduced computational efforts.

Nuclear shielding characteristics of newly developed composite metal foams: Role of CeO2 addition and foam type

In present study, new composite materials which were produced by filling open-cell aluminum foams of different thickness and pore size with various additives were surveyed with respect to photon and fast neutron shielding effectiveness. The metal foam samples were prepared in two different series (A: 30 mm thick with a pore size of 2 pores/cm and B: 10 mm thick with a pore size of 16 pores/cm) according to thickness and pore sizes, and the foams were filled with different mixtures which include Epoxy(60)-B2O3(20)-CaO(20-x)-CeO2(x); (x; 0, 5, 10, 15 and 20 wt%) chemical compositions. Gamma, X-ray and neutron measurements of the produced samples were performed using Ultra-Ge detector, linear accelerator (LINAC) and BF3 neutron detector, respectively. The gamma-transmission measurements were achieved for 30.9, 59.54, 75, 81, 276, 303, 356, 384, and 662 keV photon energies using radioactive sources of 241Am, 137Cs, 133Ba. Linear Attenuation Coefficients (LAC) of the samples were figured out with the data acquired from the measurements and MAC, HVL, Zeff and Ne values were found by way of these values. The MAC, Zeff and Ne values of the samples increased with the rising in the percentage of CeO2 added to the mixture. The energy absorption (EABF) buildup factors of the composite metal foam samples were also determined for the energy range of 0.015–15 MeV at 1–40 mfp penetration depths. It was found that the A5 and B5 samples with 20% CeO2 additive had the least EABF values. Lastly, the shielding capability of the fabricated samples against fast neutrons was specified by executing equivalent dose measurements (EAD) and calculated macroscopic cross section (∑R) values. It was established that the A2 sample had the highest absorption dose rate of 49%. The largest of the theoretically calculated ∑R values belongs to the B5 sample with 20% CeO2 additive. Generally, it was concluded that the samples in the B series, which are thinner and have more pores, have better radiation attenuation capabilities.

Synergetic effect of reduced graphene oxide and reticulated open-cell aluminum hybrid composite foam for high-performance electromagnetic wave absorption

In the present work, open-cell aluminum-reduced graphene oxide composite (Al-rGO) foam with varying concentrations of reduced graphene oxide (rGO) was fabricated through the template method and foam's electrical, mechanical, and electromagnetic shielding behavior was studied. The reticulated Al-rGO foam allows the electromagnetic wave (EMW) to go inside the structure and resulting in multiple scattering which enhances the wave absorption capacity of the material. Adding rGO into open-cell aluminium foam (OCAF) enhances its shielding properties, particularly the absorption component. The Al-rGO3 foam shows a total EMI shielding of ∼62 dB at 8.4 GHz frequency and out of which 61.34 dB (> 99% of total shielding) is the absorption component. The Al-rGO foam also exhibited maximum compressive strength of 2.96 MPa and EMI shielding of ∼62 dB at 1.5 wt% rGO, even though the electrical conductivity reduces with rGO content. This may be due to a greater degree of multiple scattering of EMW inside the cellular structure and different energy losses at rGO-Al interfaces. This work shows a new way to use the lightweight metallic structure for high EMW absorption applications with good mechanical stability in the defense and aerospace sectors.

Study on sound absorption properties of closed cell aluminum foam with different microporous structures

With the rapid development of modern society, environmental pollution is increasingly serious, among which noise pollution has become the world’s three major. At present, the methods to solve the noise problem are becoming more and more diverse. Among them, the use of porous materials for sound absorption and noise reduction is still one of the most important ways. Open-cell aluminum foam has high manufacturing costs and limited application scenarios. Therefore, some scholars have studied low-cost closed-cell aluminum foam, hoping to improve its sound absorption coefficient. Closed-cell aluminum foam is mainly used in sound insulation and has little sound absorption ability. For improving closed-cell aluminum foam sound absorption property, some scholars have researched the influence of mechanical perforation on the acoustic property of aluminum foam, but the sound absorption potential of small holes cannot be played due to the large aperture made during the process. Therefore, this paper designs and processes different aluminum foam sound absorption structures based on high-speed EDM technology and studies the effect of perforation aperture, perforation depth, and perforation rate on sound absorption peak value and sound absorption coefficient in low and middle-frequency bands (250HZ-2000Hz).

High strain-rate deformation analysis of open-cell aluminium foam

This study investigated the high-strain rate mechanical properties of open-cell aluminium foam M-pore®. While previous research has examined the response of this type of foam under quasi-static and transitional dynamic loading conditions, there is a lack of knowledge about its behaviour under higher strain rates (transitional and shock loading regimes). To address this gap in understanding, cylindrical open-cell foam specimens were tested using a modified Direct Impact Hopkinson Bar (DIHB) apparatus over a wide range of strain rates, up to 93 m/s. The results showed a strong dependency of the foam's behaviour on the loading rate, with increased plateau stress and changes in deformation front formation and propagation at higher strain rates. The internal structure of the specimens was examined using X-ray micro-computed tomography (mCT). The mCT images were used to build simplified 3D numerical models of analysed aluminium foam specimens that were used in computational simulations of their behaviour under all experimentally tested loading regimes using LS-DYNA software. The overall agreement between the experimental and computational results was good enough to validate the built numerical models capable of correctly simulating the mechanical response of analysed aluminium foam at different loading rates.

Evaluating UHMWPE-stuffed aluminium foam sandwich panels for protecting spacecraft against micrometeoroid and orbital debris impact

Robotic spacecraft shielding for protection against micrometeoroid impact is typically provided by existing structural panels, thermal insulation blankets, or reinforced component containers. Here the performance of an open cell aluminium foam core sandwich panel with intermediate ultra-high molecular weight polyethylene (UHMWPE) stuffing under hypervelocity impact of spherical aluminium projectiles was evaluated. Providing comparable structural and thermal performance as honeycomb sandwich panels, foam core sandwich panels have demonstrated improved impact shielding behaviour in existing studies. The inclusion of UHMWPE stuffing is found, through experimental testing and a comprehensive numerical study, to increase the shielding capability of foam core sandwich panels (40–80% increase in critical projectile diameter) for a modest weight penalty (25%). Compared to conventional aluminium honeycomb sandwich panels with equivalent weight, the improvement in shielding performance is >100%.

Aluminium Foam-Filled Honeycomb Crash Absorbers

Honeycomb structures are frequently used as energy absorption devices in the automotive and aerospace industry. Many studies have been conducted to optimise these structures and improve crashworthiness behaviour. This paper attempts to improve the crashworthiness behaviour of a honeycomb crash box by filling the cells with open-cell aluminium foams. Experimental tests were conducted to develop the honeycomb and aluminium foam material model and, also, to validate the finite element model by experimental data. Foam-filling the crash box allows the control of the densification zone for different impact energies using open-cell aluminium foam, which shows the main novelty of this research. In the end, the optimised structure is presented concerning the optimum number of foam-filled cells and, also, to the aluminium foam’s density that best fits this application.