Compression performances of integral-forming aluminum foam sandwich. (1st March 2022)

• Record Type: Journal Article
• Authors: Zhang, Zichen; Feng, Haomin; Xu, Tao; Xin, Wei; Ding, Jian; Liu, Nannan; Wang, Zeng; Wang, Yujiang; Xia, Xingchuan; Liu, Yongchang
• Is Part Of: Composite structures. Volume 283(2022)
• Publication Date: 2022-03-01
• Subjects: Aluminum foam sandwich -- Integral-Forming -- Compression performance; Composite construction -- Periodicals; Composites -- Périodiques; 624.18
• DOI: 10.1016/j.compstruct.2021.115090
• Languages: English
• ISSNs: 0263-8223

Abstract

Graphical abstract: Highlights: Integral-Forming Method was developed, integral-forming aluminum foam sandwich with homogeneous pores structure and favorable surface quality was successfully prepared. Compression performances of IFAFS which mainly exhibit papilionaceous and wedge failure modes are largely affected by load direction. Differences of stress distribution on solid panels and pore collapse modes are responsible for the variation of compression performance under different loading conditions. Abstract: In this study, Integral-Forming Method (IFM) of preparing aluminum foam sandwich (AFS) has been developed based on traditional melt foaming method which possesses the advantages of simple process, wide product size range and low production cost, etc. Quasi-static compression performances of the integral-forming aluminum foam sandwich (IFAFS) were evaluated by combination of experiment and finite element simulation. Real FE three-dimensional model which completely reflected the structures of IFAFS was built for the first time. Meanwhile, based on the real FE model, deformation modes and collapse mechanism of IFAFS under different loading conditions were obtained. Johnson-Cook constitutive model was used to make simulation process more accurate. The results showed that IFAFS possessed relatively high porosity, small pore diameter and homogeneous pore distribution. Loading direction and porosity were main influencing factors of their compression performances. Global collapse modes exhibited papilionaceous collapse and wedge collapse under vertical and horizontal loadings. Prediction curve by FE simulation matched well with experimental data. Post-processing results indicated that for IFAFS with similar porosities different loading directions lead to different stress distribution on solid panels, different collapse and deformation modes of the pore and global structures.