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This paper introduces a novel functionally graded metallic syntactic foam. The investigated foams are manufactured while using infiltration casting where molten A356 aluminum flows into the interstitial voids of packed expanded perlite (EP) particle beds. The partial pre-compaction of particle beds enables the creation of distinct and reproducible density gradients within the syntactic foam. In this study, the samples are produced using four gradually increasing compaction forces and are compared to non-compacted samples. X-ray imaging is used to detect the resulting spatial variation of foam density. In addition, quasi-static compression tests are performed to determine the mechanical foam properties. The results suggest that particle pre-compaction is an efficient tool for tailoring the density and mechanical properties of these novel functionally graded materials.

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This paper addresses the thermal analysis of self-propagating high temperature synthesis (SHS) in joining operations of temperature sensitive materials. A parametric Finite Element analysis of SHS is conducted, i.e. the influence of reaction rate, ignition temperature and reaction zone thickness on reaction stability and velocity is investigated. Special regard is given to surrounding materials such as amorphous alloys in joining operations. These materials act as heat sinks that conduct energy away from the reaction zone and thus diminish or even extinguish the reaction. In addition to the numerical simulation, analytical relations are developed to introduce criteria for reaction stability. Analytical and numerical results are compared for verification.