Manufacturing, characterization and applications of lightweight metallic foams for structural applications: Review

Patel, Parthkumar; Bhingole, P.P.; Makwana, Dhaval

doi:10.1016/j.matpr.2018.06.414

Cited by 43 publications

(16 citation statements)

References 61 publications

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“…Moreover, aluminum-based cellular structures are expected to experience large plastic deformation and hence to absorb important impact energy under quasi-static and dynamic loading. 9 Nonetheless, a limited number of contributions have been dedicated so far to production of AlSi10Mg-based lattice materials by AM, 3,[22][23][24][25] and to the best of the authors' knowledge, this is the first time that the printability of A357.0 into lattice materials is openly and thoroughly discussed. The lattice geometry was created by repetition of a BCCXYZ unit cell, which is shown in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

“…8 However, lattice materials have many other applications, such as heat exchangers, energy absorbers, biomedical devices, and thermal and acoustic insulators. 1,9 So far, several conventional methods have been proposed to manufacture metal-based lattice materials, including investment casting and metal wire approaches. 1,10 However, these techniques often use very complicated equipment and require subsequent assembly or bonding procedures to achieve the desired lattice structure.…”

Section: Introductionmentioning

confidence: 99%

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Technological Feasibility of Lattice Materials by Laser-Based Powder Bed Fusion of A357.0

Sola

Defanti

Mantovani

et al. 2020

3D Printing and Additive Manufacturing

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Lattice materials represent one of the utmost applications of additive manufacturing. The promising synergy between additive processes and topology optimization finds full development in achieving components that comprise bulky and hollow areas, as well as intermediate zones. Yet, the potential to design innovative shapes can be hindered by technological limits. The article tackles the manufacturability by laser-based powder bed fusion (L-PBF) of aluminum-based lattice materials by varying the beam diameter and thus the relative density. The printing accuracy is evaluated against the distinctive building phenomena in L-PBF of metals. The main finding consists in identification of a feasibility window that can be used for development of lightweight industrial components. A relative density of 20% compared with fully solid material (aluminum alloy A357.0) is found as the lowest boundary for a 3-mm cell dimension for a body-centered cubic structure with struts along the cube edges (BCCXYZ) and built with the vertical edges parallel to the growth direction to account for the worst-case scenario. Lighter structures of this kind, even if theoretically compliant with technical specifications of the machine, result in unstable frameworks.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Technological Feasibility of Lattice Materials by Laser-Based Powder Bed Fusion of A357.0

Sola

Defanti

Mantovani

et al. 2020

3D Printing and Additive Manufacturing

View full text Add to dashboard Cite

show abstract

“…Over the last decades, metallic foams have been deeply studied and different applications have been considered. Depending on the selected alloy and pore morphology, metallic foams can be of great interest for functional and structural applications [ 1 , 2 , 3 ]. Among them, one of the most remarkable applications is related to energy absorption because metallic foams combine strength and the capability of deforming at nearly constant stress levels.…”

Section: Introductionmentioning

confidence: 99%

Failure Mechanisms of an Al 6061 Alloy Foam under Dynamic Conditions

et al. 2021

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The interesting properties of Al 6061 aluminum foams have boosted the research on the correlation between foam composition and morphology and its mechanical response under dynamic conditions. In this study, ingots of an Al 6061-T4 foam were sectioned and analyzed in order to determine their microstructural and morphological characteristics, and then quasi-static and dynamic tests (10−3 to 3 × 102 s−1) were carried out to determine the material mechanical behavior. Dynamic tests, carried out by using the split Hopkinson bar, highlighted that the studied foam is characterized by a very good energy absorption capability, due to its ductile behavior. Nevertheless, the conducted research showed that cell morphology and distribution affect its mechanical behavior in dynamic conditions in which localized cell collapse may result in a decreased energy absorption and efficiency of the foam.

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“…The closed-cell foams are found to be suitable for energy absorption, blast resistance, foam core sandwich panels, foam-filled tubes, sound and noise attenuation, dampers, etc. [ 24 , 25 ]. Defects (e.g., curved cell wall, corrugation, cell shape irregularity, missing cell wall, non-uniform distribution of cell wall thickness, etc.)…”

Section: Introductionmentioning

confidence: 99%

Temperature Effects on the Compressive Behaviors of Closed-Cell Copper Foams Prepared by Powder Metallurgy

Han

Wang

et al. 2021

Materials

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A fabrication technology of closed-cell copper foams (CCCFs) based on powder metallurgy is proposed, by using the expanded polystyrene foams (EPS) spheres with the prescribed diameter as the space holder before sintering. The material characterization and the quasi-static compressive behaviors of both uniform and graded CCCFs at different temperatures were experimentally studied. A high temperature weakens the initial compressive modulus, plateau stress, and effective energy absorption for both uniform and graded CCCFs; meanwhile, the onset strain of densification and the maximum energy absorption efficiency are less sensitive to temperature, especially for the graded CCCFs. Compared with the uniform CCCF, the graded CCCF with even a small relative density exhibits superiority in terms of the effective energy absorption and the maximum energy absorption efficiency, attributed to the much larger onset strain of densification for the gradient pore arrangement. Finite element simulations based on the ideal sphere foam model can basically mimic the compressive performance of the CCCF samples. It is also found that both the decrease of pore diameter and the increase of cell wall thickness could improve the compressive performance of the CCCFs.

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Manufacturing, characterization and applications of lightweight metallic foams for structural applications: Review

Cited by 43 publications

References 61 publications

Technological Feasibility of Lattice Materials by Laser-Based Powder Bed Fusion of A357.0

Technological Feasibility of Lattice Materials by Laser-Based Powder Bed Fusion of A357.0

Failure Mechanisms of an Al 6061 Alloy Foam under Dynamic Conditions

Temperature Effects on the Compressive Behaviors of Closed-Cell Copper Foams Prepared by Powder Metallurgy

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