Steel–steel composite metal foam (S–S CMF) is a novel metal matrix composite material characterized by its high strength‐to‐weight ratio and unique mechanical and thermal properties. It is made up of hollow stainless‐steel spheres, embedded in stainless steel matrix, with 65–70% air in the structure making it effective as an insulating material. S–S CMF is being explored for use in tank cars carrying hazardous materials (HAZMATs) as a potential partial replacement for conventional carbon steel and thermal insulating material currently being used. In this study, S–S CMF material is numerically and experimentally evaluated for its thermal protection performance. Experimental studies are conducted in scaled‐down jet fire condition while numerical studies are conducted using fire dynamics simulator (FDS). Based on experimental and modeling results, as well as uncertainty studies, 13–15 mm thick S–S CMF ranging in density of about 2.5 g cc−1 tested as novel structural/insulating material meets the acceptance criterion for small‐scale simulated torch‐fire testing. Further success is anticipated in future full‐scale evaluation of 122 × 122 cm samples. The outstanding fire resistance and thermal protection of S–S CMF is attributed to the substantial volume of air trapped within the material, which correlates to its total density.
This study investigated the influence of diverse laser processing parameters on the thermophysical properties of Ti-6Al-4V and AlSi10Mg alloys manufactured via laser powder bed fusion. During fabrication, the laser power (50 W, 75 W, 100 W) and laser scanning speed (0.2 m/s, 0.4 m/s, 0.6 m/s) were adjusted while keeping other processing parameters constant. Besides laser processing parameters, this study also explored the impact of test temperatures on the thermophysical properties of the alloys. It was found that the thermophysical properties of L-PBF Ti-6Al-4V alloy samples were sensitive to laser processing parameters, while L-PBF AlSi10Mg alloy showed less sensitivity. In general, for the L-PBF Ti-6Al-4V alloy, as the laser power increased and laser scan speed decreased, both thermal diffusivity and conductivity increased. Both L-PBF Ti-6Al-4V and L-PBF AlSi10Mg alloys demonstrated similar dependence on test temperatures, with thermal diffusivity and conductivity increasing as the test temperature rose. The CALPHAD software Thermo-Calc (2023b), applied in Scheil Solidification Mode, was utilized to calculate the quantity of solution atoms, thus enhancing our understanding of observed thermal conductivity variations. A detailed analysis revealed how variations in laser processing parameters and test temperatures significantly influence the alloy’s resulting density, specific heat, thermal diffusivity, and thermal conductivity. This research not only highlights the importance of processing parameters but also enriches comprehension of the mechanisms influencing these effects in the domain of laser powder bed fusion.
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