Roll formability of aluminium foam sandwich panels

Weiß, Matthias; Abeyrathna, Buddhika; Pereira, Michael

doi:10.1007/s00170-018-1945-6

Cited by 13 publications

(3 citation statements)

References 23 publications

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“…The major deformation in roll forming is pure bending and this allows the forming of sheet materials with high material strength and low ductility. The tool contact is reduced to point contact between the top and the bottom forming rolls which can reduce interlaminar shear stress when forming a hybrid composite structure [6]. Therefore, roll forming may present a promising alternative for the rapid forming of CFRMH components [7].…”

Section: Introductionmentioning

confidence: 99%

Formability of roll-formed carbon fibre reinforced metal hybrid components and its experimental validation

Creighton

Zhang

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Carbon Fibre Reinforced Metal Hybrid (CFRMH) materials that combine a sheet metal substrate with a reinforcing carbon fibre patch represent a promising solution to reduce weight while increasing the structural and crash performance of future automotive vehicles. CFRMHs cannot be formed with conventional stamping processes and at high volumes. This currently reduces their widespread application. Roll forming is increasingly used in the automobile industry for the forming of lightweight and high-strength metal structural components. The major deformation mode in roll forming is simple bending and this reduces interlaminar shear and compressive stresses that lead to fibre failure and delamination issues when stamping CFRMH sheet materials. This work analyses the potential of applying the conventional roll forming process for the manufacture of a simple top hat section shape from CFRMH sheet. For this, first, the material is produced in a hot press and then formed to shape in a laboratory roll forming facility at room temperature. Different layup sequences are tested, and component quality is analysed after roll forming by visual inspection. The results suggest that roll forming presents a promising manufacturing method for the production of automotive components from CFRMH sheets. The roll formed open shells are joined to produce crash box structure and tested in 3-point bending. The results show that depending on the fibre orientation a significant increase in weight specific strength is achieved.

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Section: Introductionmentioning

confidence: 99%

Formability of roll-formed carbon fibre reinforced metal hybrid components and its experimental validation

Creighton

Zhang

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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“…U-bending experiments of the sandwich panels with a sheared dimple core were performed by Seong et al [16], and it was demonstrated that the sandwich panels can be successfully bent without any failures when the ratio of bending radius to total panel thickness is 3.33. Weiss et al [17] experimentally researched the roll formability of aluminum foam sandwich panels, and the results suggested that the shear deformation in roll forming was lower in comparison to V-die bending. Liang et al [7] investigated the plastic forming of the sandwich panel with bi-directionally trapezoidal cores of different sizes, and significant trends are found that the limit forming radius is decreased greatly with the decrease of the characteristic sizes of core cell unit.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study on the Plastic Forming of Doubly Curved Surfaces of Aluminum Foam Sandwich Panel Using 3D Voronoi Model

Zhang

Chen

Gao

et al. 2021

Metals

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This paper presents a numerical investigation on the plastic forming of doubly curved surfaces of aluminum foam sandwich panel (AFSP). A mesoscopic 3D Voronoi model that can describe the structure of closed-cell aluminum foam relatively realistically was established, and a series of numerical simulations using the model of the sandwich panel with a Voronoi foam core were conducted on the plastic forming of two typical doubly curved surfaces including spherical and saddle-shaped surfaces of AFSPs to analyze the deformation behaviors and the forming defects in detail. Multi-point forming experiments of spherical and saddle-shaped AFSPs with different target radii were implemented and the doubly curved panels with good forming quality were obtained. The simulated results of the surface illumination maps, the face sheet profiles, and the maximum strain differences in selected areas of the face sheet and the experimental results indicated that the Voronoi AFSP model can reflect the actual defects occurred in the plastic forming of doubly curved sandwich panels, and the high forming accuracy of the sandwich panel model was also demonstrated in terms of the shape error and the thickness variation.

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“…Such properties allow them to be employed with low energy consumption and better environmental sustainability in cars, buses, coaches and trains. Sandwich structures manufacturing is usually obtained by ex-situ bonding [13]. In this process, adhesives are employed in order to join together the external skins and the foam in an extremely easy way.…”

Section: Introductionmentioning

confidence: 99%

Interfacial Reactions between AlSi10 Foam Core and AISI 316L Steel Sheets Manufactured by In-Situ Bonding Process

Costanza

Tata

2021

Metals

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Aluminum foam sandwiches (AFS) with AlSi10 foam cores and AISI 316L steel skins are manufactured by an in-situ bonding process. The precursor of the core foam was made with the powder compacted method. The precursor and skins, coupled together, were then heated up to the melting point of the Al alloy. The gas released by the blowing agent formed hydrogen bubbles in the melt. producing the foam. Such a porous structure was kept frozen at room temperature via cooling in cold water. To optimize the process conditions, some foaming experiments have been conducted with different holding times and temperatures. Such manufactured AFS were cut, chemically etched and studied with an optical microscope associated with image analysis software to get information about pores morphology in terms of circularity and equivalent diameter. The interface AlSi10-AISI316L has been characterized by SEM and EDX to investigate the bonding conditions between cores and skins. Finally, the AFS have been polished and etched to analyze the microstructure. Quasi-static compressive tests have been performed on the AFS. Obtained results showed that the interface formed during the foaming can be characterized by the inter-diffusion of alloying elements, as confirmed by the good quality of metallurgical joints.

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Roll formability of aluminium foam sandwich panels

Cited by 13 publications

References 23 publications

Formability of roll-formed carbon fibre reinforced metal hybrid components and its experimental validation

Formability of roll-formed carbon fibre reinforced metal hybrid components and its experimental validation

Numerical Study on the Plastic Forming of Doubly Curved Surfaces of Aluminum Foam Sandwich Panel Using 3D Voronoi Model

Interfacial Reactions between AlSi10 Foam Core and AISI 316L Steel Sheets Manufactured by In-Situ Bonding Process

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