The design of metal-polymer foam adhesion and load transfer characteristics is carried out in this research work. The metal inserts are used as the load transfer component, while the foam is used as the structural element of the system. The inserts are embedded in the foam during the foaming process. Flexural testing was conducted on different metal foam configurations to establish the typical interaction trends. The load-deflection response and the mode of failure of the structure were documented. Moduli of elasticity of the system for various geometries and embedded lengths were evaluated, and behavior patterns were gleaned. Rectangular, circular, and triangular (taper-/wedgelike) inserts were used. Results show that simple taper inserts embedded in foam slabs perform better than the other shapes. Finite element analyses of the interaction under different loads were carried out. The modeling results coincided with the experimental ones hence validating the model.

Metallic anchors are used as the load transfer components for foam and sandwich composites when they are used as structural elements in design applications. The traditional method of fixation of these components is by gluing and fastening. The anchors are in the form of inserts and are imbedded in the foam during the foaming process. In this study, flexural testing was conducted on different metal anchor/foam configurations to establish typical interaction trends. The load‐deflection response, mode of failure, and fracture stresses of the structures were elucidated. Tests were conducted on foam and sandwich composites having rectangular, cylindrical, and taper geometries with different lengths. Leaf inserts were designed, manufactured, and tested inside foam and sandwich composites. Comparisons between the taper and leaf inserts are presented. Leaf inserts had better results compared with taper inserts in terms of adhesion and failure stresses. Finite element analysis (FEA) of the interactions between the inserts and the foam and sandwich composites under different loads was carried out. The FEA modeling results were very similar to the experimental results, thus validating the model. Simulations were also run with foam and sandwich composites with closeout configuration. Foam–sandwich with inserts had better adhesion and load‐bearing properties compared with same structures with closeouts. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers

Metal or solid polymer anchors are used as the load transfer components for foam and foam composites when they are used as the structural elements in design. The traditional method of fixation of these components is by fastening and adhesion. In this study, anchors were created in the form of inserts and were imbedded in the sandwich composite during the foaming process, resulting in the manufacture of three‐component composite. Flexure tests were conducted to study the effect of different geometries (rectangular, cylindrical, tapered/wedge shaped) and lengths of metal inserts on the strengths of sandwich composites. The stress strain response, mode of fracture of sandwich composite with metallic anchors was elucidated. The results showed that long tapered inserts imbedded in sandwich composite provide better load bearing and adhesion properties than other geometries. A model is presented that describes the relationship between stiffness reduction and progressive crack length of sandwich composite. Finite element analysis (FEA) of the interactions between the inserts and sandwich composites under different loads were carried out. FEA modeling and experimental results were in good agreement, thus validating the model. POLYM. COMPOS., 31:1731–1737, 2010. © 2010 Society of Plastics Engineers.

Adhesion and loading bearing properties of polyurethane (PU) foams and sandwich composite with metallic inserts are studied. Metal or solid polymer anchors are used as the load transfer components for PU foam and sandwich composites when they are used as the structural element in design. The traditional method of fixation of these components in foams is gluing and fastening. In this work, the anchors are in the form of inserts and are imbedded in the PU during the foaming process. Flexural testing was conducted on PU with and without metallic inserts to establish typical interaction trends. The load-deflection response, mode of failure, and fracture stresses of the PU structures are elucidated. Results show that long taper and leaf inserts imbedded in foam and sandwich composite provide better load carrying capacity. Comparisons between the taper and leaf inserts are documented. Leaf inserts inside a foam and sandwich composite show better results as compared to taper inserts in terms of adhesion and failure stresses. A linear elastic fracture model is also developed for the foam beam, and the fracture toughness is calculated. FEA analyses of the interaction between the inserts and the PU and sandwich composites under different loads were carried out. The FEA modeling results coincide with the experimental ones, hence validating the model.

No abstract