Structure property relationship of metal matrix syntactic foams manufactured by a binder jet printing process

Myers, Kyle; Cortes, Pedro; Conner, Brett; Wagner, Timothy R.; Hetzel, Brian P; Peters, Kai

doi:10.1016/j.addma.2014.12.003

Cited by 22 publications

(12 citation statements)

References 13 publications

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“…The second involves incorporating porosity through hollow particles instead of gas bubbles to provide a reinforcing effect to each pore and also to precisely control the size and volume fraction of porosity. Such hollow particle filled foams are called syntactic foams [7][8][9]. While these two developments are complementary, metal matrix syntactic foam core sandwich composites have not been fabricated or studied until now.…”

Section: Introductionmentioning

confidence: 98%

Syntactic foam core metal matrix sandwich composite under bending conditions

Omar¹,

Xiang²,

Gupta³

et al. 2015

Materials & Design

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The present work aims at characterizing a metal matrix syntactic foam core sandwich composite under threepoint bending conditions. The sandwich comprises alumina hollow particle reinforced A356 alloy syntactic foam with carbon fabric skins. Crack initiation in the tensile side of the specimen causing failure of the skin, followed by rapid failure of the core in the direction applied load, is observed as the failure mechanism. Crack propagation through the alumina particles is observed in the failed specimens instead of interfacial failure. The average maximum strength, flexural strain and stiffness were measured as 91.2 ± 5.6 MPa, 0.49 ± 0.06% and 20.6 ± 0.7 GPa respectively. The collapse load is theoretically predicted using mechanics of sandwich beams. Experimental values show good agreement with theoretical predictions.

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Section: Introductionmentioning

confidence: 98%

Syntactic foam core metal matrix sandwich composite under bending conditions

Omar¹,

Xiang²,

Gupta³

et al. 2015

Materials & Design

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“…However, the as-fabricated MMSF still contains the mesh inserts, resulting in an anisotropic structure. Myers et al [80] designed an innovative route to synthesize MMSF based on 3D printing. Microballoon samples were made by binder jet 3D printing, then they were cured through heat treatment.…”

Section: The Pressure-less Infiltration Methods (Dpli)mentioning

confidence: 99%

“…Diverse authors, among them Yaseer Omar et al [11,102] and Lamanna et al [100] successfully processed a sandwich core MMSF panel and they proved its versatility. Furthermore, this route enables modification, including 3D printing steps as in the work of Myers et al [80]. The 3D printing, sintering and pressure-less infiltration promoted a less restricted synthesis technique.…”

Section: The Pressure-less Infiltration Methods (Dpli)mentioning

confidence: 99%

“…Since the amount of matrix material is determined by the interstitial space of the preform, this technique is not usually applied for synthesizing MMSF with large matrix volume fractions. Moreover, infiltration molds cannot support complex geometries thus MMSF processed by MIT have strong shape limitations [80]. However, it is possible to process MMSF with the highest volume fraction of fillers.…”

Section: Molten Metal Infiltration Technique For Processing Mmsfmentioning

confidence: 99%

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Molten Metal Infiltration Methods to Process Metal Matrix Syntactic Foams

S-de-la-Muela

Cambronero

Ruiz‐Román

2020

Metals

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Metal matrix syntactic foams (MMSF) are foam composites obtained by filling hollow and/or porous particles into a metal matrix. MMSF are promising materials in defense, aerospace, automotive, marine and engineering applications. Mechanical and physical properties of MMSF can be tailored to reach better structural and/or functional behaviors by fitting processing and tailoring parameters. Some of these parameters are: reinforcement size, volume fraction, distribution of reinforcements and chemical composition. Three techniques are available to manufacture MMSF: Stir casting/vortex method (SC), powder metallurgy (P/M) and infiltration routes. Infiltration process is by far the main employed for making MMSF, it allows a large range of reinforcement (30 vol % to 78 vol %) and offers great advantages compared to other techniques. This paper reviews infiltration routes used to date, their advantages and drawbacks, the main processing parameters of each route, and a relation of representative studies developed to date on the synthesizing of MMSF by molten infiltration processes.

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“…The porous structures possible from 3D printing have also been exploited to achieve metal-ceramic composite structures. Essentially, a porous ceramic matrix is first 3D printed using one or the other common techniques and then the metal component is developed by infiltration [16]. The binder jet process in particular is very effective in processing ceramic materials allowing build complex shapes with minimal waste.…”

Section: Introductionmentioning

confidence: 99%

Mechanism of Bonding in Seashell Powder Based Ceramic Composites Used for Binder-Jet 3D Printing

Singamneni¹,

MP²,

Guen³

et al. 2018

Bioceram Dev Appl

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Singamneni et al., Bioceram Dev Appl 2018, 8:1 DOI: 10.4172/2090 Volume AbstractBinder-jet 3D printing responses of sea-shell powder based ceramic composites have been evaluated considering the material consolidation mechanisms and mechanical characterisations. Initial experimental printing trials are done manually, varying the composition of the composite powders from 5% to 50% of the seashell powder and the rest plaster. Overall, the seashell and plaster combinations worked well in terms of achieving the necessary green strengths within the binder-jet process conditions. Scanning electron microscopy and 3-point bending results indicated no significant loss of properties at lower levels of the seashell component, but the strength decreased beyond the 25% mark. The optimum levels of seashell powder are found to be within 15-20% by weight in terms of the best compression strengths. Neat sea-shell powder however goes too sticky immediately after the interaction with the binder liquid and does not show evidence of any binding mechanism that can be accelerated.

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Structure property relationship of metal matrix syntactic foams manufactured by a binder jet printing process

Cited by 22 publications

References 13 publications

Syntactic foam core metal matrix sandwich composite under bending conditions

Syntactic foam core metal matrix sandwich composite under bending conditions

Molten Metal Infiltration Methods to Process Metal Matrix Syntactic Foams

Mechanism of Bonding in Seashell Powder Based Ceramic Composites Used for Binder-Jet 3D Printing

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