Synthesis of open-cell metal foams by templated directed vapor deposition

Queheillalt, Douglas T.; Hass, D. D.; Sypeck, David J.; Wadley, H.N.G.

doi:10.1557/jmr.2001.0143

Cited by 105 publications

(52 citation statements)

References 25 publications

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“…[3][4][5][6][7] Recently, a cellular solid becomes more attractive for multifunctional applications, where high loading capacity is required together with other functionalities: e.g., ultra-light structure for compact cooling, energy absorption and vibration control. 8) This material design requires a structural topological design for efficient heat capacity together with loading capacity in the most efficient manner. The intervening space is used for flowing fluids to remove heat and for energy absorption by spatially distributing plastic deformations.…”

Section: Introductionmentioning

confidence: 99%

In-Plane Compression Response of Regularly Cell-Structured Materials

2004

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A quasi-static compression response of regularly cell-structured materials is studied by experimental and analytical procedures. A hexagonal close-packed cell-structure is fabricated by mechanical joining under compressive stress. The nominal stress-strain curve is typical to the cellular solids. It has three stages in deformation: linear elastic, plastic collapsing and densification regions. SEM-Servopulser is also used to describe the sequence of deformation images during uniaxial compressive test. Elasto-plastic model can predict quantitatively the compression behavior of copper cell-structured materials. Besides the relative density, the loading condition plays an important role on the deformation mode change and loading capacity. With increasing the contact radius ratio to cell wall thickness, the symmetric deformation changes itself to asymmetric deformation.

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Section: Introductionmentioning

confidence: 99%

In-Plane Compression Response of Regularly Cell-Structured Materials

2004

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“…The average peak stress of Inconel foams is higher than that of the other opencell nickel-based foams of similar relative density which were fabricated by the different foaming processes such as the space holder method [12], slurry coating of carbon foams [6], chromium deposition on Ni foams [28], and electron beam vapour deposition [13] (see Fig. 8).…”

Section: Quantitative Relation Between Relative Density and Mechanicamentioning

confidence: 99%

“…8). Note that while the foam produced by the electron beam vapour deposition technique [13] has a comparable peak strength, its fabrication cost is also higher. The comparison with other fabrication processes demonstrates the potential of this slurry coating technique to produce low cost Inconel foams with relatively higher strength-to-weight ratios.…”

Section: Quantitative Relation Between Relative Density and Mechanicamentioning

confidence: 99%

“…Note that the solid loading of the slurry is Φ = 0.76. Space holder [12] Slurry coating of carbon foam [6] Chromium deposition on Ni foam [28] Electron beam vapour deposition [13] …”

Section: Effect Of Unit Cell Size On Sound Absorption Propertiesmentioning

confidence: 99%

“…However, the production of foams for applications involving exposure to high temperature environments requires that superalloys be used as foam materials. Open-cell foams of Ni-based superalloys have been produced by using various solid state processing methods, such as the space holder method [12] and electron beam vapour deposition [13]. However, little research reported the use of the slurry coating method for the fabrication of such foams.…”

Section: Introductionmentioning

confidence: 99%

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The effect of slurry composition on the microstructure and mechanical properties of open-cell Inconel foams manufactured by the slurry coating technique

Raghavan

et al. 2017

Materials Science and Engineering: A

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Open-cell nickel-based alloy foams are attractive materials for applications such as sound damping and heat exchange, especially those involving exposure to high temperature environments. This study demonstrated the potential of a developed slurry coating technique for manufacturing open-cell Inconel alloy foams, and then investigated the effect of slurry composition on the microstructure and mechanical properties of the foams. It was found that the compressive properties of the foam can be quantitatively related to its relative density using the empirical equations. The deformation behaviour of the foam is bending-dominated; and unit cell struts undergo brittle fracture after the elastic region. Increasing the slurry solid loading leads to a higher average bulk foam density and more non-uniform crush bands in the foam under compression. Compared to other fabrication processes, this slurry coating technique is able to to produce open-cell Inconel foams with relatively higher strength-to-weight ratios. This study also revealed that the sound absorption capability of the foam increases when its unit cell size is reduced.

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Cellular Metals Manufacturing

Wadley¹

2002

Adv. Eng. Mater.

241

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Manufacturing Methods OverviewAs the engineering applications of cellular metals grows, many methods for their manufacture are being developed. [1] They result in materials that can be classified by the size of their cells, variability in cell size (stochastic or periodic), the pore type (open or closed) and the relative density of the structure. Figure 1 summarizes the range of cell size and relative density for materials created by established and emerging manufacturing methods. Those with high relative density, r/ r s >0.5 (where r is the cellular metals density and r s is that of the solid from which it is made) include Gasars made by the solidification of metal-H 2 alloys [2] and expanded, entrapped gas materials. [3] Interest in the structural uses of both materials has declined because of the difficulty of creating the low relative densities (0.05±0.20) needed for these applications. [4] Manufacturing methods based upon the foaming of a liquid metal, either by injecting a gas (the CYMAT process) [5] or by the decomposition of gas releasing particles (e.g. the Alporus or Alulight materials) [6] are the most widely used for making stochastic cellular aluminum. Efforts are underway to extend the method to other metals. Both approaches result in closed cell stochastic foams with cell sizes in the 0.5 to 15 mm range and relative densities from 0.04 to 0.4.Open cell, stochastic nickel foams are widely used for the electrodes and current collectors of metal ± metal hydride batteries. Closed cell, periodic aluminum honeycomb is extensively used for the cores of light, stiff sandwich panel structures. Interest is now growing in other cell topologies and potential applications are expanding. For example cellular metals are being evaluated for impact energy absorption, for noise and vibration damping and for novel approaches to thermal management. Numerous methods for manufacturing cellular metals are being developed. As a basic understanding of the relationships between cell topology and the performance of cellular metals in each application area begins to emerge, interest is growing in processes that enable an optimized topology to be reproducibly created. For some applications, such as acoustic attenuation, stochastic metal foams are likely to be preferred over their periodically structured counterparts. Nonetheless, the average cell size, the cell size standard deviation, the relative density and the microstructure of the ligaments are all important to control. The invention of more stable processes and improved methods for on-line control of the cellular structure via in-situ sensing and more sophisticated control algorithms are likely to lead to significant improvements in foam topology. For load supporting applications, sandwich panels containing honeycomb cores are much superior to those utilizing stochastic foams, but they are more costly than stochastic foam core materials. Recently, processes have begun to emerge for making open cell periodic cell materials with triangular or pyramidal truss topologies. Th...

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Synthesis of open-cell metal foams by templated directed vapor deposition

Cited by 105 publications

References 25 publications

In-Plane Compression Response of Regularly Cell-Structured Materials

In-Plane Compression Response of Regularly Cell-Structured Materials

The effect of slurry composition on the microstructure and mechanical properties of open-cell Inconel foams manufactured by the slurry coating technique

Cellular Metals Manufacturing

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