Investigation of a Template‐Based Process Chain for Investment Casting of Open‐Cell Metal Foams

Kubelka, Pierre; Körte, Fabian; Heimann, Johann; Xiong, Xin; Jost, Norbert

doi:10.1002/adem.202100608

Cited by 7 publications

(4 citation statements)

References 51 publications

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“…efficient. [27] This study aims to produce a Cu lattice structure with a combination of AM and investment casting and study the mechanical and energy absorption properties of these structures both experimentally and with the help of computer analysis. The casting method is the most well-known method for production.…”

Section: Doi: 101002/adem202300447mentioning

confidence: 99%

“…In other words, to utilize a potential free‐form fabricating method, indirect rapid manufacturing techniques, such as the combination of 3D printing and investment casting, are determined to be affordable and efficient. [ 27 ] This study aims to produce a Cu lattice structure with a combination of AM and investment casting and study the mechanical and energy absorption properties of these structures both experimentally and with the help of computer analysis. The casting method is the most well‐known method for production.…”

Section: Introductionmentioning

confidence: 99%

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Experimental and Simulation Investigation on Energy Absorption of Cu Casting Lattice Structure during Compression

2023

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This investigation aims to assess the mechanical behavior and energy absorption properties of the Cu lattice structures made by investment casting method experimentally and by finite element method (FEM) simulation. The casting pattern of lattice structures is additively manufactured with 2.0, 2.5, and 3.0 mm diameters and the lattice structures produced by investment casting of Cu. Then a uniaxial compression test is applied to measure maximum compressive strength, energy absorption density, efficiency, and specific energy absorption. The simulation and the experimental results indicate that the abovementioned properties of the lattice structures have a significant improvement and properties developments will rise by increasing the diameter of the struts. The mechanical characterization has done for Cu lattice structure with 3.0 mm strut diameter, which endures a stress of 242 MPa at the densification strain and the maximum tolerated stress of 404 MPa. The energy absorption density of this lattice structure is 67 MJ m−3 and has a specific energy absorption of 28 J g−1 followed by an energy absorption efficiency around 70%. The simulation result shows a mathematical connection between the unit cells and the final lattice structures in terms of maximum tolerated stresses, which can help the prediction of the mechanical behavior of these structures.

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Section: Doi: 101002/adem202300447mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental and Simulation Investigation on Energy Absorption of Cu Casting Lattice Structure during Compression

2023

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“…Пористость в полученном таким способом пенометалле колеблется от 80 до 97 %, а размер пор варьируется от 4 до 0,5 мм [22,23]. Механические свойства металлической пены, изготовленной модифицированным методом литья по выплавляемым моделям, выше, чем у ретикулированной; допустимая сжимающая нагрузка значительно выше, чем у ретикулированного пенометалла [24]. Возможен различный химический состав, высокая прочность на сжатие при высокой деформационной закалке.…”

Section: получение металлической пены путем литья по выжигаемым моделямunclassified

A systematic review of processing techniques for cellular metallic foam production

Sharma,

Joshi,

Rajpoot

2023

Metal Working and Material Science

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Introduction. The paper presents a comprehensive overview of the manufacturing methods, materials, properties, and challenges associated with cellular metallic foams, primarily focusing on aluminum and titanium-based foams. Cellular metallic foams are gaining interest due to its unique combination of low density, high stiffness, and enhanced energy absorption capabilities. Cellular metallic foam is renowned for its special combinations of physical and mechanical characteristics, containing their increased stiffness, specific strength at high temperatures, light weight, and good energy absorption at relatively low plateau stress. It has extensive uses in the automotive, shipbuilding and space industries. It has high porosity, low relative density and high strength, which increases performance of the product. The aerospace and automotive industries require a material with a high strength-to-weight ratio. Methods. To meet this need, many metal foam production methods have been developed, such as melt route method, deposition method and powder metallurgy method. Melt route method is widely used to manufacture metallic foam as compared to other methods. Results and Discussion. In the production of aluminum foams, the melt route method is usually used. Titanium hydride (TiH2) has been a popular foaming agent, but its high decomposition rate and cost limitations have led to the development of alternative foaming agents, such as CaCO3 (calcium carbonate). Titanium foam is often manufactured using the space holder method. This method involves mixing titanium powder with a space holder material, forming a preform, and then sintering to remove the space holder and produce a porous structure as the space holder method allows for precise control over the properties of the foam, including pore size, porosity, and relative density. Results also indicate that porosity in cellular metallic foams can range from 50 % to 95 %, as reported in various journals. Pore structures can include mixed types, open cells, and closed cells, each offering different mechanical and thermal properties. It is also observed from various literature sources that relative density, which is the ratio of the foam's density to the bulk material's density, varies from 0.02 to 0.44 based on the production method used.

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“…The maximum efficiency identifies the optimal foam giving maximum absorbed energy for a certain maximum load level or, conversely, the minimum load for a certain value of absorbed energy. This method is useful in most applications and has been applied to several classical materials, including metal foams such as magnesiumbased [3], aluminum-based [4], and titanium-based foams [5], as well as with innovative solutions such microcellular porous solids [6], density-graded polymeric [7] foams, polymeric [8] and aluminum honeycombs [9], lattice structures [10], auxetic structures [11], and open-cell lightweight structures [12]. The cushioning curves, instead, relate the maximum acceleration-defined as the G-value-in an impact to the stress: in the end, this G-value is simply the inverse of the efficiency.…”

Section: Introductionmentioning

confidence: 99%

A Generic Model to Assess the Efficiency Analysis of Cellular Foams

Avalle

2024

Materials

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One of the main types of uses of cellular materials is for energy absorption and dissipation in applications, such as safety and packaging, to protect people and goods during impact situations. In such cases, the use of cellular materials is justified by their capacity to largely deform under limited loads. This is often achieved, alone or within energy absorbing structures, with the additional advantage of cheap components that are relatively simple to manufacture and assemble. As in most engineering applications, weight reduction is sought after and, as in the case of other materials, this objective can be attained by optimizing the use of the material. Optimization of a cellular material for energy absorption means obtaining an optimal mechanical characteristic that can be obtained by properly designing it in terms of the type of base material and cell properties. Cell properties are mainly related to density and their optimal selection can be made by means of energy criteria. The aim of the present paper is to discuss such optimality criteria based on what are termed efficiency diagrams to produce an effective design tool. Additionally, based on empiric observations on the behavior of several classes of polymeric foams, a simplified selection method is proposed to hasten the selection criteria.

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Investigation of a Template‐Based Process Chain for Investment Casting of Open‐Cell Metal Foams

Cited by 7 publications

References 51 publications

Experimental and Simulation Investigation on Energy Absorption of Cu Casting Lattice Structure during Compression

Experimental and Simulation Investigation on Energy Absorption of Cu Casting Lattice Structure during Compression

A systematic review of processing techniques for cellular metallic foam production

A Generic Model to Assess the Efficiency Analysis of Cellular Foams

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