Prediction and prevention of fracture defect in plastic forming for aluminum foam sandwich panel

Zhang, Xi; Chen, Qing-Min; Cai, Zhongyi

doi:10.1016/j.jmrt.2021.08.147

Cited by 14 publications

(6 citation statements)

References 27 publications

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“…Zhang et al [113] found that AFS panels can keep their pore structure during MP deformation, as shown in Figure 11c. The risk of core fracture can be reduced by adopting multi-step forming and increasing the core relative density.…”

Section: Mold Pressing Processmentioning

confidence: 96%

“…Figure 11. (a) MP of AFS panel[32] (reproduced with permission from John Wiley and Sons); (b) mold pressed AFS parts[32] (reproduced with permission from John Wiley and Sons); (c) deformed AFS panels[113] (reproduced with permission from Elsevier); (d-g) macroscopic morphologies and pore structure before and after MP[114] (reproduced with permission from Springer).…”

mentioning

confidence: 99%

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Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Fu,

2024

Materials

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Closed-cell aluminum foams have many excellent properties, such as low density, high specific strength, great energy absorption, good sound absorption, electromagnetic shielding, heat and flame insulation, etc. As a new kind of material, closed-cell aluminum foams have been used in lightweight structures, traffic collision protections, sound absorption walls, building decorations, and many other places. In this paper, the recent progress of closed-cell aluminum foams, on fabrication techniques, including the melt foaming method, gas injection foaming method, and powder metallurgy foaming method, and on processing techniques, including powder metallurgy foaming process, two-step foaming process, cast foaming process, gas injection foaming process, mold pressing process, and integral foaming process, are summarized. Properties and applications of closed-cell aluminum foams are discussed based on the mechanical properties and physical properties separately. Special focuses are made on the newly developed cast-forming process for complex 3D parts and the improvement of mechanical properties by the development of small pore size foam fabrication and modification of cell wall microstructures.

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Section: Mold Pressing Processmentioning

confidence: 96%

mentioning

confidence: 99%

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Fu,

2024

Materials

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“…Various reports previously studied by researchers 1–3 examined the performance, failure, and design recommendations of honeycombs, grids, and truss structures 4 . Saifullah et al, 5 Ashraf et al, 6 Zhang et al, 7 He et al, 8,9 Vaziri et al, 10 Song et al 11,12 have examined the flexural, vibration, and low‐velocity impact properties of various types of honeycomb sandwiches and corrugated sandwiches made from various materials using theoretical simulation and experimental methods, respectively. The findings demonstrated that sandwich structures had extremely high engineering value and excellent mechanical performance.…”

Section: Introductionmentioning

confidence: 99%

Effects of polymethacrylimide foam reinforced aluminum honeycomb sandwich under quasi‐static compression

Song

Xiong

Yin

et al. 2023

Polymers for Advanced Techs

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In this study, aluminum honeycomb cells were filled with polymethacrylimide (PMI) foam of high strength and stiffness, and carbon fiber reinforced composite (CFRC) skins were added to create a composite sandwich structure. Nine types of specimens with varying cell node spacing and foam density were constructed, and stiffness equations were derived. To compare the performances of aluminum honeycomb and PMI foam sandwich structures, their compressive responses were examined using edgewise and flatwise compression tests. Moreover, the failure was analyzed using finite element methods (FEM). Analytical and numerical models were used to investigate the size effects of rib width, rib angle, and node spacing.

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“…Morton [28] built a micromechanical model based on Laguerre-Voronoi tessellations of a polymer foam to better understand the mechanical response of foam structures subjected to complex loading conditions. Zhang et al [29,30] successfully used a mesoscopic 3D Voronoi model to investigate forming of aluminium foam sandwich panels (AFSP) in Abaqus/explicit. They found that the Voronoi AFSP models could reflect the actual defects, shape error, and thickness variation occurring in the plastic forming of doubly curved sandwich panels [29], and that core cracking could be predicted with the use of the Ko fracture criterion [31].…”

Section: Introductionmentioning

confidence: 99%

Experimental Tests and Numerical Simulations on the Ballistic Impact Response of a Highly Inhomogeneous Aluminium Foam

Brekken

Vestrum²,

Dey³

et al. 2022

Materials

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A sandwich structure is a composite material consisting of thin skins encapsulating a cellular core. Such structures have proven to be excellent energy absorbents and are frequently found in various types of protection. Even so, few studies exist in the open literature on the response of the core material itself under extreme loadings such as blast and impact. Since a blast load is usually accompanied by numerous fragments, it is important to understand and be able to predict the ballistic impact resistance of the often highly inhomogeneous cellular core materials in design. In this study, the ballistic impact response of an aluminium foam with a complex cell structure has been investigated both experimentally and numerically. First, an extensive material test program involving compression tests on cubic specimens loaded in the thickness direction of the foam was carried out to reveal the mechanical properties of the material. In addition, several of the specimens were scanned before testing using X-ray Micro Computed Tomography (XRMCT) to map the multi-scale topology and morphology of the material. These data were later analysed to extract density-variation plots in many different material orientations. Second, ballistic impact tests were conducted using a gas gun where rigid spheres were launched towards aluminium foam plates, and the ballistic limit velocity and curve of the foam material were established. Finally, numerical simulations of both the material tests and the ballistic impact tests were carried out using LS-DYNA and different modelling approaches based on the XRMCT data. It will be shown that, independent of the modelling strategy applied, good agreement between the experimental impact tests and the numerical predictions can be obtained. However, XRMCT data are important if the final goal is to numerically optimise and improve the behaviour of inhomogeneous foams with respect to energy absorption, thermal isolation, or similar properties.

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Prediction and prevention of fracture defect in plastic forming for aluminum foam sandwich panel

Cited by 14 publications

References 27 publications

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Effects of polymethacrylimide foam reinforced aluminum honeycomb sandwich under quasi‐static compression

Experimental Tests and Numerical Simulations on the Ballistic Impact Response of a Highly Inhomogeneous Aluminium Foam

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