Metal Foam Research Articles

MICROSTRUCTURE AND WEAR BEHAVIOR CHARACTERIZATION OF STIR-CAST ALUMINUM 6063 ALLOY AND ITS FOAM: A COMPARATIVE STUDY

In this research work, aluminum 6063 alloy foam was synthesized through stir casting using varying amounts of titanium hydride as a foaming agent. A comparative microstructural and wear behavior analysis of stir-cast aluminum 6063 alloy and its foam is presented. The oxide and aluminide phases present as intermetallic compounds in the stir-cast aluminum 6063 alloy foam ensure the stability of the synthesized foam. In order to optimize the effect of wear parameters on the tribological properties of stir-cast aluminum 6063 alloy foam, the L933 orthogonal array (OA) was designed and modeled statistically. The tribological properties of stir-cast aluminum 6063 alloy and its foam were evaluated by pin-on-disc tests. The optimal tribological properties of the synthesized foam are 0.29 coefficient of friction, 8.6 N frictional force, and 0.00025 mm3/N-m specific wear rate. The tribological properties of stir-cast aluminum 6063 alloy foam are superior to those of aluminum 6063 alloy and comparable to other aluminum foams described in the literature.

Performance optimization of hydrogen storage reactors based on PCM coupled with heat transfer fins or metal foams

Metal hydride is a type of solid hydrogen storage material that offers excellent hydrogen absorption and desorption reaction properties. However, there is a strong thermal effect during the reaction process when the materials are applied in reactors. Thus, effective thermal management techniques are crucial for promoting efficient reactions. Prior studies on the subject have shown that phase change materials can be coupled with metal hydride reactors to transfer the reaction heat. To further enhance the transfer of heat and reaction efficiency of the metal hydride reactors based on phase change materials, this study explored heat transfer enhancement methods on the phase change materials side, including adding heat transfer fins and discussing the fin parameters and composite foam metal. The findings of the study showed that in comparison to the reactor without fins, the absorption rate of adding 10 sets of fins can increase by 28%, and as the number of fins increased to 14, this value could increase to 39.4%. The use of Y-shaped fins did not substantially improve the reaction rate, mainly due to the sufficient number of straight fins, and the heat transfer area reaching the limit of the fin enhanced the process of heat transport. Thus, the improved method of using copper foam is further considered. Compared with the reactor with and without fins, the absorption rate of the copper foam coupled reactor is increased by 23.4% and 61.3%, respectively.

Impact behavior of the SCS panel with hybrid energy absorbing components: Experimental and analytical studies

A new steel-concrete-steel panel with front aluminum foam layer and rear energy absorbing connector (SCS-FL-EAC) was firstly developed. The dynamic behavior of SCS-FL-EAC was studied through conducting drop-weight impact tests. Three stages of impact process of SCS-FL-EAC were identified. The aluminum foam layer and energy absorbing connector were crushed under impact loading. The aluminum foam layer reached densification, and a local indention was observed beneath the projectile. Plastic hinges were also found at the corners of the pleated steel plate of the energy absorbing connector. The SCS panel exhibited the combination of bi-linear global flexural deformation and local deformation. Furthermore, the effects of aluminum foam layer on the impact resistant performances of SCS-FL-EAC were investigated. The results indicated that the inclusion of the aluminum foam layer effectively mitigated inertial effects and reduced the maximum impact force. Additionally, the SCS-FL-EAC demonstrated improved impact-resistant performances with an increased thickness of the aluminum foam layer. Furthermore, an analytical model was proposed to predict the force and displacement responses of SCS-FL-EAC subjected to impact load, and the predicted impact responses showed good agreement with experimental results.

Design and preparation of composite bipolar plates with synergistic conductive networks of graphite and metal foam

Graphite composite bipolar plate (BP) have limited conductivity, which makes them less than ideal for extensive application in proton exchange membrane fuel cell (PEMFC). In traditional graphite composite BP, the construction process of the conductive network is entirely random. To enhance conductivity, it is typically necessary to increase the content of conductive fillers or incorporate high aspect ratio carbon nanomaterials to optimize the density of the conductive network. In this work, we manufactured a highly conductive composite bipolar plate with synergistic conductive networks of graphite and metal foam (MF). With a synergistic conductive network, the ASR of CuG80-20ppi decreased to 7.7 mΩ cm2. Additionally, thermal conductivity increased to 24.76 W/(m·K), and in-plane conductivity reached 294.1 S/cm at 80 wt% mass fractions of conductive filler, using 20 ppi copper foam as the metallic conductive network. CuG80-20ppi exhibited a flexural strength of 52.2 MPa. G80 and CuG80-20ppi have the 80 wt% conductive filler and are molded into BP with parallel flow fields. CuG80-20ppi enhances the current density of PEMFC by 0.132 W/cm2 and reduces the ohmic impedance by 5.25%. Therefore, the findings of this study offer valuable insights for the enhancement of composite BP conductivity, while simultaneously ensuring the stability and continuity of the synergistic conductive network. A novel approach is presented to enhance the electrical conductivity of graphite composite bipolar plate (BP) for proton exchange membrane fuel cells (PEMFCs). By embedding metal foam as a supplementary conductive network within the graphite matrix, a synergistic conductive architecture is achieved. This innovation significantly reduces the area specific resistance (ASR) to 7.7 mΩ cm2 and boosts thermal conductivity to 24.76 W/(m·K). The resulting CuG80-20ppi BP, with 80 wt% conductive filler, exhibits improved mechanical strength and conductivity, contributing to a 0.132 W/cm2 increase in PEMFC current density and a 5.25% reduction in ohmic impedance. This work highlights the potential of metal foam integration to enhance BP conductivity and PEMFC performance.

Liquid Metal-Based Elastomer Composite with Selective Switchable Adhesion to Solids.

Selective switchable adhesion has recently attracted much attention due to its wide applications in transfer printing, information transfer, and flexible electronics. However, selective adhesive materials often have a complex adhesion or preparation process, which limits their use. To overcome this problem, this study prepares a composite of liquid metal foam and polydimethylsiloxane (PDMS) with selective photocontrolled adhesion, which can directly adhere to solids at room temperature. Utilizing the photoinduced phase transition of liquid metals, solid adhesion can be regulated by changing the backing layer modulus of the adhesive layer. Since the phase transition process is gradually completed by heat transfer from the illuminated side to the backlight side that adheres to the solid, the melting area on the backlight side can be regulated by controlling the light time, which determines the adhesion regulation area. Therefore, the accuracy of the adhesion regulation can reach less than 0.9 mm without relying on the accuracy of the infrared light. Moreover, based on the selective switchable adhesion, the selective transfer of solids with different scales can be achieved at room temperature. The findings of this study may provide strategies for the simple preparation of selective adhesive materials and the improvement of control accuracy.

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.

Experimental and Numerical Evaluation of Calcium-Silicate-Based Mineral Foam for Blast Mitigation

Cellular materials such as aluminum and polyurethane foams are recognized for their effectiveness in energy absorption. They commonly serve as crushable cores in sacrificial cladding for blast mitigation purposes. This study delves into the effectiveness of autoclaved aerated concrete (AAC), a lightweight, porous material known for its energy-absorbing properties as a crushable core in sacrificial cladding. The experimental set-up features a rigid frame made of steel measuring 1000 × 1000 × 15 mm3 with a central square opening (300 × 300 mm2) holding a 2 mm thick aluminum plate representing the structure. The dynamic response of the aluminum plate is captured using two high-speed cameras arranged in a stereoscopic configuration. Three-dimensional digital image correlation is used to compute the transient deformation fields. Blast loading is achieved by detonating 20 g of C4 explosive set at 250 mm from the plate’s center. The study assesses the mineral foam’s absorption capacity by comparing out-of-plane displacement and mean permanent deformation of the aluminum plate with and without the protective solution. Six foam configurations (A to F) are tested experimentally and numerically, varying in the foam’s free space for expansion relative to its total volume. Results show positive protective effects, with configuration F reducing maximum deflection by at least 30% and configuration C by up to 70%. Foam configuration influences energy dissipation, with an optimal lateral surface-to-volume ratio (ζ) enhancing protective effects, although excessive ζ leads to non-uniform foam crushing. To address the influence of front skin deformability, a non-deformable front skin has been adopted. The latter demonstrates an increased effectiveness of the sacrificial cladding, particularly for ζ values above the optimal value obtained when using a deformable front skin. Notably, using a non-deformable front skin increases maximum deflection reduction and foam energy absorption by up to approximately 30%.

Development and performance evaluation of a novel solar mid-and-low temperature receiver/reactor with packed metal foam

Solar-driven hydrogen production from methanol decomposition (MD) is an important method of storing solar energy as clean fuels and improving the solar energy utilization efficiency. Catalyst preparation is one of the key steps, but conventional Cu-ZnO-Al2O3 particle catalysts lead to uneven reactor temperature, reducing the efficient conversion of solar energy into fuels. To alleviate this challenge, a monolithic catalyst utilizing packed foamy copper as a carrier is developed with exceptional thermal and mass transfer properties. The experimental results validate its excellent performance in hydrogen production using MD. The absolute conversion increases by an average of 12.11 % at 250 °C and further by 14.43 % at 270 °C compared to the particle catalyst. Based on these findings, a novel solar reactor is proposed, and a multi-field coupling model is built. The comparative results verify the performance advantage of the developed solar thermochemical receiver/reactor with packed metal foam-based catalyst. It maintains high conversion rates and solar-to-fuel energy efficiency, while alleviating overheating problems caused by traditional particle catalysts. Under the design conditions, the new reactor significantly improves the absolute conversion of methanol and the energy efficiency of solar-to-fuel conversion by 4.57 % and 3.00 %, respectively, resulting in 92.64 % and 67.56 %. This study provides a theoretical basis and technical solution for more stable and efficient use of mid-and-low temperature solar energy.

Metal Hydride Storage Systems: Approaches to Improve Their Performances

AbstractMetal hydrides provide a safe and efficient way to store hydrogen. However, current metal hydride storage systems, i.e., hydrides incorporated within a storage tank, are far from efficient. Depending on the design, (dis)charging rates may be very long. However, this can be significantly improved by implementing strategies tackling the issue of heat management at the level of: i) the metal hydride bed, and ii) the overall storage system design. This review summarises recent progress in tackling heat management of hydride systems. In this respect, modeling has emerged as a powerful tool. In particular, simulation results show that the compaction of hydride powders with binders and the use of metal foams are both effective in lifting the poor thermal conductivity of hydride beds. For tank designs, cylindrical shapes remain the preferred choice because of the flexibility and ease of supplementing heat management with fins and tubular heat exchangers. The addition of phase change materials to the hydride tank can lead to further heat storage, but any add‐on to simple hydride tanks can only lead to cumbersome systems. It is still a fine art to tune the thermal conductivity of hydride beds while selecting a suitable metal hydride alloy composition.

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

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

Maglev tunnel hoods can prevent speed-driven sonic booms

Foam metal tunnel hoods could allow maglev trains to travel faster without compromising safety or comfort.

Influence of Cell Wall Material and Cell Numbers on Mechanical Properties of Closed-Cell Aluminum Foams

Influence of Cell Wall Material and Cell Numbers on Mechanical Properties of Closed-Cell Aluminum Foams

Current and emerging methods for manufacturing of closed pore metal foams and its characteristics: a review

Current and emerging methods for manufacturing of closed pore metal foams and its characteristics: a review

Oil-Resistant Underoil Superhydrophilic Metallic Foams for Lampblack Prefiltration.

Superwetting/repelling coatings have been utilized to address the issue of oil contamination on lampblack prefiltration metallic foam by both academia and industry. Nevertheless, the widely adopted superamphiphobic coatings are currently costly and suffer from poor wear resistance. In this study, we propose an oil-resistant underoil superhydrophilic (LSH) coating by a dip-coating method. The subsequent heating process at 200 °C for 5 min strengthens the designed coating based on lithium polysilicate cross-linking reinforcement. The LSH coating with a minimal water contact angle up to 3.4° under soybean oil can spontaneously achieve oil desorption within 7 s under water. Moreover, the coating retains its superhydrophilicity after enduring 900 friction cycles under a 500 g load or being immersed in 50 °C soapy water for 48 h. Hence, the LSH coating with great durability on metallic foam for lampblack prefiltration resulted in a 9.3% decrease in the oil absorption weight ratio after a 17-day cooking test. This work underscores the potential application of the LSH coating in lampblack prefiltration components, presenting promising technological advancements in self-cleaning for the catering industry.

Characterisation and modification of the porous metal foams used for the EN 15051-2 dustiness rotating drum test.

Two approaches were used to evaluate the performance of the reticulated metal foams used to size select and collect dust generated in the dustiness rotating drum tester according to the EN 15051-2 standard "Workplace exposure-Measurement of the dustiness of bulk materials-Rotating drum test". Firstly, the detailed performance of the metal foams was measured in a calm air chamber using a polydisperse aerosol of glass particles and assessed against the respirable conventions described in the EN 481 standard "Workplace atmospheres-Size fraction definitions for measurement of airborne particles". Secondly, the performance of the EN 15051-2 metal foam size selection for the respirable fraction was compared using the rotating drum dustiness test, with that of a cyclone set-up, using 4 polydisperse glass powders of different size distribution and dustiness potential. The research discusses further improvements to the EN 15051-2 standard and an approach to more closely match the EN 481 convention. In general, for the respirable fraction, the tests in this study demonstrated a conservative oversampling by the current EN 15051-2 metal foam set-up in comparison with the EN 481 convention. Calculations and tests showed an improved fit was achieved by reducing the inner diameter of the flanges separating the metal foams and the filter. This study also showed the importance of sealing the circumference of the metal foams when testing highly dusty powders. A direct comparison of the respirable dustiness fraction, measured by the current EN 15051-2 metal foams set-up and by a cyclone set-up, showed broad agreement. However, for extremely dusty powders, the metal foams can clog, and dust can accumulate between the 20 and 80 pores per inch foams.

Efficient and broadband sound absorption properties of slotted aluminum foam

To enhance the sound absorption performance of aluminum foam, a slotted structure was developed. Firstly, the theoretical model of sound absorption for the slotted aluminum foam was established by the transfer matrix method. Secondly, the finite element model was established using COMSOL software to predict the sound absorption coefficient. The reliability of the theoretical and finite element models was validated through impedance tube experiments. The sound absorption mechanism is investigated by analyzing the internal sound field. Finally, the sound absorption properties of aluminum foam with other slot patterns are investigated. Additionally, the factors that influence sound absorption properties are investigated. The results indicate that the slots alter the sound pressure distribution within the material, inducing a pressure diffusion effect. When sound waves enter the interior of the material through the narrow slots, they are absorbed and dissipated by the matrix material on the sides of the slots. The sound absorption coefficient can be improved by increasing the thickness, slot scale, and slot depth of the slotted aluminum foam. Specifically, when the slot depth is 15 mm, and the slot width is 5 mm, the average sound absorption coefficient of incompletely slotted aluminum foam in the frequency range of 1000 ∼ 6300 Hz is 0.86, which can realize broadband sound absorption. With the increase of slot depth, the sound absorption peak becomes more pronounced.

Achieving metallurgical bonding in steel faceplate/aluminum foam sandwich via hot pressing and foaming processes: interfacial microstructure evolution and tensile behavior

This study introduces an innovative approach to fabricating aluminum foam sandwich with aluminized steel faceplates through metallurgical bonding. The process involves the use of foamable precursor, prepared via melt stirring, and subsequent hot pressing and foaming, offering a cost-effective and industrially feasible method for producing lightweight structural materials and connection of steel/aluminum dissimilar metals. This study focuses on exploring the changes in the microstructure of the bonding interface before and after foaming, and revealing the impact of these changes on the tensile results. Foaming experiment shows that foamable sandwiches have superior foaming ability, and the core layer density after foaming is between 0.283 and 0.591 g/cm ³. Microstructural characterization results demonstrate that, during the hot pressing process, fine equiaxed grains are observed on the iron side of the interface, indicating dynamic recrystallization occurred. The formation of a small amount of η-Al5Fe2 at the interface is a primary factor causing the deflection of the fracture path. Subsequently, during the foaming process, intermetallic compounds (IMCs) θ-Al13Fe4, τ5-Al7Fe2Si, and β-Al4.5FeSi formed sequentially, mainly determined by the diffusion reaction of silicon elements. The formation of these IMCs led to an increase in microhardness at the interface and a decrease in shear strength. Digital image correlation was utilized to examine strain distribution under tensile loading. The result indicates that the damage accumulation is characterized by the formation and expansion of strain bands, with failure manifested as the interconnection of these strain bands.

Study on the Process of Preparing Aluminum Foam Sandwich Panel Precursor by Friction Stir Welding

In recent years, high-performance lightweight and multifunctional aluminum foam sandwiches (AFSs) can be successfully applied to spacecraft, automobiles, and high-speed trains. Friction stir welding (FSW) has been proposed as a new method for the preparation of AFS precursors in order to improve the cost-effectiveness and productivity of the preparation of AFS. In this study, the AFS precursors were prepared using the FSW process. The distribution of foaming agents in the AFS precursors and the structure and morphology of AFS were observed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray energy dispersive spectroscopy (EDS). The effects of the temperature and material flow on the distribution of the foaming agent during the FSW process were analyzed through experimental study and numerical simulation using ANSYS Fluent 19.0 software. The results show that the uniform distribution of the foaming agent in the matrix and excellent densification of AFS precursor can be prepared when the rotation speed is 1500 r/min, the travel speed is 25 mm/min, the tool plunge depth is 0.2 mm, and the tool moves along the retreating side (RS). In addition, the experimental and numerical simulations show that increasing the welding temperature improves the uniformity of foaming agent distribution and the area of AFS precursor prepared by single welding, shortening the thread length inhibits the foaming agent from reaching the upper sandwich plate and moving along the RS leads to a more uniform distribution of the foaming agent. Finally, the AFS with porosity of 74.55%, roundness of 0.97, and average pore diameter of 1.192 mm is prepared.

Active vibration control of metal foam reinforced agglomerated graphene nanoplatelets nanocomposite truncated conical shells with piezoelectric layers

This study examines active vibration control (AVC) in a truncated conical shell composed of metal foam reinforced with agglomerated graphene nanoplatelets and integrated with piezoelectric layers functioning as sensors and actuators. Both complete and partial agglomeration states are considered based on the Eshelby–Mori–Tanaka approach, and the mechanical properties of the porous core are characterized using a closed-cell metal foam model. The governing equations of motion are derived using Hamilton’s principle, based on the two-dimensional axisymmetric elasticity theory, and solved through the finite element method coupled with the Newmark method. Vibration mitigation is achieved using a fractional-order fuzzy proportional–integral–derivative (PID) controller. A comprehensive parametric study is conducted, examining the effects of geometric dimensions, various boundary conditions, reinforcement parameters (including weight fraction, distribution patterns, and agglomeration parameters), and porosity parameters (including pore size, and porosity pattern) on the vibration properties of the shell. Numerical simulations are performed to assess the effectiveness of the proposed AVC system in reducing structural vibrations compared to a constant velocity feedback control approach. The velocity feedback controller reduced central deflection from 12.65 to 5.089 μ m , while a fractional-order fuzzy PID controller further improved it to 2.348 μ m , representing a 53.86% enhancement over the velocity feedback controller.

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.