Laser forming of sandwich panels with metal foam cores

2019 ◽  
Vol 31 (2) ◽  
pp. 022606 ◽  
Author(s):  
Tizian Bucher ◽  
Steven Cardenas ◽  
Ravi Verma ◽  
Wayne Li ◽  
Y. Lawrence Yao
Keyword(s):  
Metal Foam ◽  
Sandwich Panels ◽  
Laser Forming

Laser Forming of Metal Foam Sandwich Panels: Effect of Panel Manufacturing Method

2019 ◽  
Vol 141 (5) ◽  
Author(s):  
Tizian Bucher ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Ravi Verma ◽  
Wayne Li ◽  
...  
Keyword(s):  
Metal Foam ◽  
Numerical Models ◽  
Sandwich Panels ◽  
Weight Ratio ◽  
Industrial Applications ◽  
Laser Forming ◽  
Process Conditions ◽  
Foam Core ◽  
Wide Range ◽  
The Impact

Sandwich panels with metal foam cores have a tremendous potential in various industrial applications due to their outstanding strength-to-weight ratio, stiffness, and shock absorption capacity. A recent study paved the road toward a more economical implementation of sandwich panels, by showing that the material can be successfully bent up to large angles using laser forming. The study also developed a fundamental understanding of the underlying bending mechanisms and established accurate numerical models. In this study, these efforts were carried further, and the impact of the foam core structure, the facesheet and foam core compositions, and the adhesion method on the bending efficiency and the bending limit was investigated. These factors were studied individually and collectively by comparing two fundamentally different sandwich panel types. Thermally induced stresses at the facesheet/core interface were thoroughly considered. Numerical modeling was carried out under different levels of geometric accuracy to complement bending experiments under a wide range of process conditions. Interactions between panel properties and process conditions were demonstrated and discussed.

3D Laser Forming of Metal Foam Sandwich Panels

2020 ◽  
Author(s):  
Tizian Bucher ◽  
Connor Finn ◽  
Ravi Verma ◽  
Wayne Li ◽  
Y. Lawrence Yao
Keyword(s):  
Metal Foam ◽  
Sandwich Panels ◽  
Absorption Capacity ◽  
Laser Forming ◽  
Process Conditions ◽  
Practical Engineering ◽  
3D Deformation ◽  
Panel Thickness ◽  
The Impact ◽  
Scan Length

Abstract Metal foam sandwich panels have been subject of many concept studies, due to their exceptional stiffness, light weight, and crash absorption capacity. Yet, the industrial production of the material has been hampered by the fact that it is challenging to bend the material into practical engineering shapes. Only recently it has been shown that bending of metal foam sandwich panels is possible using lasers. It was shown that the material can be bent into Euclidean (2D) geometries, and the governing laser-induced bending mechanisms were analyzed. This study was focused on laser forming of metal foam sandwich panels into non-Euclidean (3D) geometries. It was investigated whether the knowledge about the bending mechanisms translates to 3D deformation, and whether the combination of process parameters that were identified for 2D laser forming are still appropriate. Moreover, the impact of the laser scan length was determined by comparing different scan patterns that achieve the same 3D geometries. It was shown that 3D deformation could be induced for both the bowl and saddle shapes, the two most fundamental non-Euclidean geometries. The amount of laser-induced bending and in-plane strains vary depending on process conditions and thus bending mechanisms. Lastly, the laser scan length was shown to become more important for metal foam sandwich panels, where the panel thickness tends to be large.

3D Laser Forming of Metal Foam Sandwich Panels

2020 ◽  
Vol 142 (8) ◽  
Author(s):  
Tizian Bucher ◽  
Connor Finn ◽  
Ravi Verma ◽  
Wayne Li ◽  
Y. Lawrence Yao
Keyword(s):  
Metal Foam ◽  
Sandwich Panels ◽  
Absorption Capacity ◽  
Laser Forming ◽  
Process Conditions ◽  
Practical Engineering ◽  
3D Deformation ◽  
Panel Thickness ◽  
The Impact ◽  
Scan Length

Abstract Metal foam sandwich panels have been the subject of many concept studies, due to their exceptional stiffness, light weight, and crash absorption capacity. Yet, the industrial production of the material has been hampered by the fact that it is challenging to bend the material into practical engineering shapes. Only recently, it has been shown that bending of metal foam sandwich panels is possible using lasers. It was also shown that the material can be bent into Euclidean (2D) geometries, and the governing laser-induced bending mechanisms were analyzed. This study was focused on laser forming of metal foam sandwich panels into non-Euclidean (3D) geometries. It was investigated whether the bending mechanisms and process parameters identified for 2D laser forming translate to 3D deformation. Additionally, the impact of the laser scan length was determined by comparing different scan patterns that achieve the same 3D geometries. It was shown that laser forming could induce 3D deformation necessary for both bowl and saddle shapes, the two fundamental non-Euclidean geometries. The amount of laser-induced bending and in-plane strains vary depending on process conditions and the governing bending mechanisms. Lastly, the laser scan length was shown to become more important for metal foam sandwich panels, where the panel thickness tends to be large.

Laser Forming of Metal Foam Sandwich Panels: Effect of Panel Manufacturing Method

2019 ◽  
Author(s):  
Tizian Bucher ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Ravi Verma ◽  
Wayne Li ◽  
...  
Keyword(s):  
Metal Foam ◽  
Numerical Models ◽  
Sandwich Panels ◽  
Weight Ratio ◽  
Industrial Applications ◽  
Laser Forming ◽  
Process Conditions ◽  
Foam Core ◽  
Wide Range ◽  
The Impact

Abstract Sandwich panels with metal foam cores have a tremendous potential in various industrial applications due to their outstanding strength-to-weight ratio, stiffness, and shock absorption capacity. A recent study paved the road towards a more economical implementation of sandwich panels, by showing that the material can be successfully bent up to large angles using laser forming. The study also developed a fundamental understanding of the underlying bending mechanisms and established accurate numerical models. In this study, these efforts were carried further, and the impact of the foam core structure, the facesheet and foam core compositions, as well as the adhesion method on the bending efficiency and bending limit was investigated. These factors were studied individually and collectively by comparing two fundamentally different sandwich panel types. Thermally-induced stresses at the facesheet/core interface were thoroughly considered. Numerical modeling was carried out under different levels of geometric accuracy, to complement bending experiments under a wide range of process conditions. Interactions between panel properties and process conditions were demonstrated and discussed.

scholarly journals Laser Forming of Sandwich Panels With Metal Foam Cores

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Tizian Bucher ◽  
Steven Cardenas ◽  
Ravi Verma ◽  
Wayne Li ◽  
Y. Lawrence Yao
Keyword(s):  
Power Plants ◽  
Metal Foam ◽  
Sandwich Panels ◽  
Laser Forming ◽  
Process Conditions ◽  
Foam Core ◽  
Mechanism Analysis ◽  
Forming Process ◽  
Solar Power Plants ◽  
The Impact

Over the past decade, laser forming has been effectively used to bend various metal foams, opening the possibility of applying these unique materials in new engineering applications. The purpose of the study was to extend laser forming to bend sandwich panels consisting of metallic facesheets joined to a metal foam core. Metal foam sandwich panels combine the excellent shock-absorption properties and low weight of metal foam with the wear resistance and strength of metallic facesheets, making them desirable for many applications in fields such as aerospace, the automotive industry, and solar power plants. To better understand the bending behavior of metal foam sandwich panels, as well as the impact of laser forming on the material properties, the fundamental mechanisms that govern bending deformation during laser forming were analyzed. It was found that the well-established bending mechanisms that separately govern solid metal and metal foam laser forming still apply to sandwich panel laser forming. However, two mechanisms operate in tandem, and a separate mechanism is responsible for the deformation of the solid facesheet and the foam core. From the bending mechanism analysis, it was concluded on the maximum achievable bending angle and the overall efficiency of the laser forming process at different process conditions. Throughout the analysis, experimental results were complemented by numerical simulations that were obtained using two finite element models that followed different geometrical approaches.

scholarly journals Thermally Induced Mechanical Response of Metal Foam During Laser Forming

2018 ◽  
Vol 140 (4) ◽  
Author(s):  
Tizian Bucher ◽  
Adelaide Young ◽  
Min Zhang ◽  
Chang Jun Chen ◽  
Y. Lawrence Yao
Keyword(s):  
Temperature Gradient ◽  
Mechanical Response ◽  
Metal Foam ◽  
Mechanical Performance ◽  
Image Correlation ◽  
Laser Forming ◽  
Experimental Proof ◽  
Thermally Induced ◽  
The Impact ◽  
Different Levels

To date, metal foam products have rarely made it past the prototype stage. The reason is that few methods exist to manufacture metal foam into the shapes required in engineering applications. Laser forming is currently the only method with a high geometrical flexibility that is able to shape arbitrarily sized parts. However, the process is still poorly understood when used on metal foam, and many issues regarding the foam's mechanical response have not yet been addressed. In this study, the mechanical behavior of metal foam during laser forming was characterized by measuring its strain response via digital image correlation (DIC). The resulting data were used to verify whether the temperature gradient mechanism (TGM), well established in solid sheet metal forming, is valid for metal foam, as has always been assumed without experimental proof. Additionally, the behavior of metal foam at large bending angles was studied, and the impact of laser-induced imperfections on its mechanical performance was investigated. The mechanical response was numerically simulated using models with different levels of geometrical approximation. It was shown that bending is primarily caused by compression-induced shortening, achieved via cell crushing near the laser irradiated surface. Since this mechanism differs from the traditional TGM, where bending is caused by plastic compressive strains near the laser irradiated surface, a modified temperature gradient mechanism (MTGM) was proposed. The densification occurring in MTGM locally alters the material properties of the metal foam, limiting the maximum achievable bending angle, without significantly impacting its mechanical performance.

Experimental Study of Sandwich Panels Subjected to Foam Projectile Impact

2013 ◽  
Vol 535-536 ◽  
pp. 501-504
Author(s):  
Mohd Azman Yahaya ◽  
Dong Ruan ◽  
Guo Xing Lu
Keyword(s):  
Metal Foam ◽  
Impact Load ◽  
Sandwich Panels ◽  
Equal Mass ◽  
Aluminium Foam ◽  
Element Analysis ◽  
Measuring Device ◽  
Back Face ◽  
History Of ◽  
The Impact

Similar blast loading characteristics can be obtained using impact of aluminium foam projectiles, which enables blast tests to be mimicked in a laboratory scale and in a safer environment. The purpose of this study is to determine the back-face deflection history of aluminium sandwich panels experimentally by aids of a laser displacement meter when panels are subjected to the impact of metal foam projectiles. This information was usually determined using finite element analysis (FEA) due to the difficulty in the experiment. The projectiles are cylindrical ALPORAS aluminium foam with diameter of 37 mm, length of 50 mm and nominal relative density of 10%. The sandwich panels consist of two 1 mm aluminium face-sheets and an aluminium honeycomb as the core. There are five different core configurations with a brand name of HEXCEL. The projectiles are fired towards the centre of the sandwich panels at different velocities using a gas gun. During the tests, a laser optical displacement measuring device is used to record the history of the back-face deflection experimentally. The deflection of the back-face is found to reach the maximum before coming to rest at a smaller value. The final back-face deflections of the sandwich panels show exponential relationship with the projectile impulse. The final deflections are compared with the deflection of monolithic plates with equal mass. The sandwich panels deflect less than the monolithic plate with an equal mass up to a critical value but continue to increase significantly afterwards. Care should be taken when using sandwich panels as protective structures against foam projectiles as beyond this point, the monolithic plates outperform the sandwich panels in absorbing the impact load.

Tensile properties of composite metal foam and composite metal foam core sandwich panels

2020 ◽  
pp. 109963622094288
Author(s):  
Jacob Marx ◽  
Afsaneh Rabiei
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Metal Foam ◽  
Failure Strain ◽  
Sandwich Panels ◽  
Metal Foams ◽  
Bond Line ◽  
Upper And Lower Bounds ◽  
Foam Core ◽  
The Face

Steel-steel composite metal foam (SS-CMF) and composite metal foam core sandwich panels (SS-CMF-CSP) were manufactured and tested under quasi-static tension. The SS-CMF-CSP were manufactured by attaching stainless steel face sheets to a SS-CMF core using solid-state diffusion bonding. SEM imaging was used to inspect the microstructure of SS-CMF and compare it to that of SS-CMF-CSP. The results indicate a cohesive bond line at the interface of the core and the face sheets. The bare SS-CMF samples had an ultimate tensile strength between 75–85 MPa and a failure strain between 7.5–8%. The normalized tensile strength of the SS-CMF was approximately 24 MPa/(g/cm3), 410% higher than other comparable metal foams, with a specific energy absorption of 0.95 J/g under tension. The uniform porosities and strong bonding between the sphere wall and matrix seem to be the strengthening factor of SS-CMF under tension when compared to other metal foams. The ultimate tensile strength of the SS-CMF-CSP was 115% stronger than the bare SS-CMF at 165 MPa with an average failure strain of 23%. The normalized strength of the SS-CMF-CSP was 52% higher than the bare SS-CMF. The modulus of elasticity was approximated using the rule of mixtures for the SS-CMF and the SS-CMF-CSP and the experimental results were found to lie within the calculated upper and lower bounds.

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