Indian Institute of Technology Bombay
Aluminium foams offer an exceptional strength-to-weight ratio and energy absorption capacity, but variations in the cell structure often hinder performance, limiting their broader industrial application. The addition (ex-situ) or formation (in-situ) of specific particles during foam processing can stabilize the foam by reducing cell coalescence and liquid drainage during foaming. This study explores the potential of in-situ formed Al3Zr particles to enhance the stability and properties of AA6061 closed-cell foams. The microstructural analysis confirmed the presence of Al3Zr particle clusters along the plateau borders, which inhibited cell coalescence and wall thinning. As a result, the composite foams demonstrated a 37% increase in plateau stress and a 56% improvement in energy absorption capacity, achieving a mean energy absorption efficiency of 78.5% compared to base AA6061 foams. The coefficient of thermal expansion mismatch between the particles and the matrix emerged as the primary strengthening mechanism, leading to a 12.9% enhancement in yield strength. Mesoscale ex-situ compression testing revealed brittle failure with premature cell fracture due to microcell formation and secondary phases at the cell edge region.
Abstract
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Poster
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