Study on the Microstructure and Compression of Composite Metal Foam Core Sandwich Panels
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SANDWICH panel materials are important in building lightweight and high rigidity structures. Sandwich panels are regularly made with solid face sheets surrounding a porous core that provides strength to the body under flexure without much additional weight. Metal foams can be an optimal material for the core as they provide a porous structure with relatively high strength and low weight.[1–4] Metal foam core sandwich panels can be made using a variety of techniques depending on the material makeup of both the core and face sheets. This includes bonding the face sheets to the foam core using adhesive epoxy and traditional metal joining techniques such as welding, brazing, or solid-state diffusion bonding.[5–10] Each method has its own benefits and drawbacks such as environmental limitations of the epoxy layer, localized heat affected zones within the weldment, and low shear strength of the brazing bond layer. Welding of the metal foams will also reduce the material porosity and, in turn, negate the benefits of using a metal foam core. This has made it
JACOB MARX and AFSANEH RABIEI are with the Advanced Materials Research Lab, Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695. Contact e-mail: [email protected] Manuscript submitted April 22, 2020. Article published online August 25, 2020 METALLURGICAL AND MATERIALS TRANSACTIONS A
difficult to find a consistent bonding method for manufacturing metal foam core sandwich panels. Diffusion bonding, however, can generally be easily modified for use on metal foams. Until recently, most metal foam sandwich panels have used aluminum foam cores. The structure and bond between the core and the face sheets can be improved by using a high strength foam core, such as composite metal foam. Composite metal foam (CMF) is one of the strongest class of metal foams and can offer weight savings to mechanical designs without sacrificing strength.[4,11,12] CMF is comprised of hollow metal spheres surrounded with a metallic matrix. The two components can be made of any metal or alloy combination. CMF’s large strength-to-weight ratio, unique impact energy absorption capabilities, and passive thermal insulating make it a leading candidate material for sandwich panel structures.[4,11,13–15] The metallic matrix between the hollow spheres creates a larger surface area to adhere face sheets to CMF’s surface compared to other metal foam cores. The face sheets can help support CMF under tensile forces and improve the material’s corrosion resistance in a variety of engineering and structural applications. In this work steel-steel composite metal foam core sandwich panels (SS-CMF-CSP) were manufactured by attaching a SS-CMF core to stainless steel face sheets. The stainless steel face sheets were applied and tested using two attachment methods: adhesive and diffusion
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bonding. Although the quasi-static compression of SS-CMF has been well reported in the past, the results of SS-CMF-CSP under such loading have not yet been reported
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