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Brothers, Alan Harold |
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Processing and Properties of Advanced Metallic Foams |
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Book Whole |
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2006 |
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251 |
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Since the development of the first aluminum foams in the middle of the 20th century [178],
great advances have been made in the processing and fundamental understanding of metallic
foams. As a result of these advances, metallic foams are now penetrating a number of applications
where their unique suite of properties makes them superior to solid materials, such as lightweight
structures, packaging and impact protection, and filtration and catalysis [3]. The purpose of this
work is to extend the use of metallic foams in such applications by expanding their processing
to include more sophisticated base alloys and architectures.
The first four chapters discuss replacement of conventional crystalline metal foams with
ones made from high-strength, low-melting amorphous metals, a substitution that offers potential
for achieving mechanical properties superior to those of the best crystalline metal foams,
without sacrificing the simplicity of processing methods made for low-melting crystalline alloys.
Three different amorphous metal foams are developed in these chapters, and their structures
and properties characterized. It is shown for the first time that amorphous metal foams, due to
stabilization of shear bands during bending of their small strut-like features, are capable of compressive
ductility comparable to that of ductile crystalline metal foams. A two-fold improvement
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in mechanical energy absorption relative to crystalline aluminum foams is shown experimentally
to result from this stabilization.
The last two chapters discuss modifications in foam processing that are designed to introduce
controllable and continuous gradients in local foam density, which should improve mass efficiency
by mimicking the optimized structures found in natural cellular materials [64], as well as facilitate
the bonding and joining of foams with solid materials in higher-order structures. Two
new processing methods are developed, one based on replication of nonuniformly-compressed
polymer precursors, and the other based on nonuniform chemical milling of uniform foams, and
each method is demonstrated through the production of low-density aluminum foams having
simple model density gradients. |
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Northwestern University |
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Ph.D. thesis |
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1933 |
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