Investigation of Energy Absorption Behavior of Light Sandwich Panel with Nickel/Polymer Open‐Cell Foam Core during Compression

Abstract

This investigation aims to assess the mechanical behavior and energy absorption properties of the light sandwich panels made of open‐cell polymer and nickel/polymer foam. A portion of the ultralightweight foam sandwich panels (14.23 g) is produced by 3D printing and electrodeposition methods with 35, 45, and 55 seeds numbers, which lead to 4, 5, and 6 pores per inch (PPI); then a uniaxial compression test is applied to measure maximum compressive strength, strength‐to‐weight ratio, energy absorption density, efficiency, and complementary energy. The results indicate that compared with typical open‐cell nickel foams and polymer precursors when the thickness of the nickel layer is about 50 micrometers, the aforementioned properties of the sandwich panel shows a significant improvement. Improvement of properties changes by increasing PPI and CAD seed numbers. In a nickel/polymer sandwich panel with 6 PPI, the first maximum compressive strength, specific energy absorption, and energy absorption efficiency reach 0.93 (MPa), 0.93 (J.boldg−1), and 60%, respectively. 3D‐RP‐Ni‐6 improves 3D‐RP‐6 first maximum compressive strength and specific energy absorption by six times and two times, respectively. These significant improvements in the properties of these sandwich panels make these advanced materials a suitable candidate for the high strength applications.

Mechanical Response of Open‐Cell Metal Foams with Single‐ and Multilayer Shell during Uniaxial Compression Test

“…According to ref. [47] and ISO 13 314, [ 55 ] in examining the mechanical properties of metal foams, the densification strain () is a significant factor as it ends the porous behavior and makes the material act like its bulk. Moreover, the plateau region of metal foams is the area of stress–strain graph that is responsible for the absorbed energy of these metallic foams.…”

“…Also, the increasing discrepancies between the prediction by the shock theory were due to the higher level of densification strain that can be achieved experimentally than is predicted analytically when using simple theories. Moreover, Rohani Nejad et al [47] produced a new generation of sandwich panels with open-cell metal foam cores through additive manufacturing of polymers and electroforming of nickel and reported that the strength and energy absorption properties of these sandwich structures will increase by increasing the pores per inches (PPI) of these novel materials. Furthermore, Reda et al [20] DOI: 10.1002/adem.202301995 Metal foams are one of the unique materials that need more attention in terms of mechanical and microstructural characterizations.…”

Investigation on mechanical properties of nickel open cell metal foam after heat treatment

“…In general, the foams can be subjected to mechanical loading conditions, therefore, high strength is considered as a crucial factor and investigating of the mechanical behavior of metal foams is considered imperative 12 , 17 – 20 . The mechanical behavior of cellular structures is governed by their internal architecture 21 . Various new methods and manufacturing technologies have developed recently for the production of these recyclable materials which depends on the characteristics expected from the porous media.…”

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

“…[10][11][12] Many production methods have been applied from the beginning of their appearance until today because of the complex geometry, the importance of being near network parts, and control of pore size, shape, and struts. Production methods based on metallization of the precursor were one of the first used methods, [13] such as chemical vapor deposition (CVD), [11] physical vapor deposition (PVD), electroless plating, [14] electrodeposition, [15] and dip coating. Moreover, additive manufacturing (AM) [16] or 3D printing is a promising and approximately newfangled technique for creating lattice structures.…”