Indian Institute of Technology Bombay
Metal foams are lightweight and high-specific strength cellular materials used in various engineering applications. Aluminium foam sandwich materials use metal foams as a core material that combines the light weightiness and flexural rigidity properties and are used for structural and automobile applications. Metal foams processed through the liquid metallurgy route are stabilized by adding particles. The stabilizing particles are often distributed in the clustered form in the cell network. The present study investigates the effect of this particle distribution on the deformation behaviour of closed-cell aluminium metal foams. The intricate foam cell structure was generated using the spherical particle inflation method [1] and analyzed using explicit dynamics analysis based on finite element simulations in Abaqus© software. We compare three distinct foam simulation models: unit cell, microtomography reconstructed, and stochastic generation. The experimental data was used to model the particle and foam cell structure. The simulation results were then validated against experimental findings. The simulations revealed that a uniform particle distribution enhanced the mechanical properties of closed-cell aluminium composite foams. This occurs by lowering stress concentration effects and strengthening the cell walls. However, clustered particles were observed to hinder this benefit. Crack initiation and propagation were more prevalent in these areas, lowering the foam's ductility. Furthermore, simulations indicated a tendency towards brittle failure when particle clusters formed near cell walls and foam edges.
Abstract
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