Functional aluminium matrix syntactic foams filled with lightweight expanded clay aggregate particles

Kemény, Alexandra; Leveles, Borbála; Károly, Dóra

doi:10.1016/j.matpr.2020.12.164

Cited by 9 publications

(4 citation statements)

References 18 publications

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“…The foam filling resulted in 24% increment in the energy absorption and ensured more controlled failure modes with suppressed classic loss of mechanical stability of the tubes. Keme ´ny et al (Ref 45,46) modified the liquid state low pressure infiltration method to produce in situ CMFs filled Al tubes. In this technology, the infiltration of the LECPs happens in a thin-walled Al tube resulting in perfect bonding between the CMF and the tube to be filled (in classic (Ôex-situÕ) cases the CMFs are produced separately, inserted into the tube, and fixed by gluing, soldering or by close fitting).…”

Section: Introductionmentioning

confidence: 99%

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Orbulov

Szlancsik

Kemény

et al. 2022

J. of Materi Eng and Perform

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This paper is dealing with the production and investigation (structural and mechanical) of composite metal foams (CMFs) with AlSi9MgMn matrix and ~60 vol% of different nominal diameter light expanded clay particles (LECPs) filler. The main aim was to produce a cheap CMF grade for automotive industry. The samples were produced by liquid state low pressure infiltration. Cubic samples were manufactured from the produced CMF blocks for structural (optical microscopy, scanning electron microscopy and energy-dispersive x-ray spectrometry (EDS)) and for mechanical (compression) investigations and tests. The CMFs were investigated in as-cast and in T6 heat-treated conditions. The macrostructural investigations showed homogenous structure and sufficient quality infiltration. On the microscopic scale, the EDS investigations revealed a complex interface layer affected by chemical reactions between the matrix material and the filler particles. The compressive test proved the classic foam-like mechanical behavior of the CMFs (with long plateau region). A relationship (valid for both the as-cast and T6 heat-treated conditions) was found between the characteristic properties and the nominal diameter of the filler. Based on these results, the LECPs filled CMFs are ideal candidates for automotive applications with tailorable properties.

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Section: Introductionmentioning

confidence: 99%

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Orbulov

Szlancsik

Kemény

et al. 2022

J. of Materi Eng and Perform

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“…Composite metal foams are hybrid structures with several important advantages, such as high specific strength, low density, and excellent mechanical energy absorption, while providing thermal and chemical stability [1][2][3].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Bending Properties of Ex situ Functional Metal Foams

Pados,

Kemény,

Károly

et al. 2024

Period. Polytech. Mech. Eng.

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In each industry, compromises have to be made when choosing materials. Lower-density materials have a significant advantage in the automotive sector, especially due to rising fuel prices, since weight reduction can lower overall fuel consumption. The advantageous properties of metal foams, such as low density, high specific strength, and excellent energy absorption, should be researched and exploited in as many areas and ways as possible. This research aims to perform and evaluate the bending tests of ex situ functional metal foams: aluminum alloy matrix (AlSi7Mg) was used, which was filled with Ø2.5–3.0 mm lightweight expanded clay aggregate particles and surrounded by thin-walled aluminum tubes (AlMgSi0.5) with a wall thickness of 2 mm and an outer diameter of Ø32 mm. Empty tubes, foam-filled tubes (with and without structural epoxy adhesive) and metal matrix syntactic foams were compared based on their flexural strength and energy absorption capacity. Quasi-static three-point bend tests were carried out up to 25 mm deflection. The foam-filled tubes with epoxy adhesive showed an average of 6% increase in flexural strength compared to the foam-filled tubes without adhesive and a 145% increase compared to the metal matrix syntactic foams.

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“…Thin-walled hollow particles like alumina, silicon dioxide, cenosphere spheres, and glass bubbles are common filler materials [11][12][13][14]. However, natural-based pumice, expanded perlite, and expanded clay granules have also been utilized by certain investigation teams by reason of their unique porous/cellular inner structure, low cost, and easy accessibility in recent times [15][16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

An experimental examination of the dry drilling machinability features of cellular glass‐filled new‐generation metallic composite foams

Bolat,

Ergene,

Akgun

et al. 2023

Materialwissenschaft Werkst

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On the way to the real industrial applications of the metal matrix composite foams, the machining issue is highly critical in terms of dimensional accuracy, surface quality, and design diversity. Therefore, especially for lightweight automotive and aerospace components, the drilling machinability properties of cellular glass‐added aluminum composite foams were examined in this paper, and this is the first initiative in the literature specific to millimeter‐scale glass and aluminum‐zinc matrix combination. To comprehend the drilling properties, the outputs of thrust force, cylindricity, material removal rate, specific cutting coefficient, circularity error, damage factor, surface roughness, and chip formation were measured elaboratively. The results showed that cylindricity and damage factor of foams elevated with the increased feed rates (from 0.05 mm×rev−1 to 0.2 mm×rev−1) and cutting speeds (from 25 m×min−1 to 100 m×min−1). Maximum thrust force value reached up to 150 N for 0.2 mm×rev−1 feed and 25 m×min−1 cutting speed. Besides, specific cutting coefficient values ranged between 360 MPa and 114 MPa. The highest surface roughness of 58.3 μm was obtained with the lowest cutting speed of 25 m×min−1, and the long/continuous chip structure converted into a separate/short structure based on rising feed and cutting speeds.

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Functional aluminium matrix syntactic foams filled with lightweight expanded clay aggregate particles

Cited by 9 publications

References 18 publications

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Investigation of the Bending Properties of Ex situ Functional Metal Foams

An experimental examination of the dry drilling machinability features of cellular glass‐filled new‐generation metallic composite foams

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