Processing and Properties of Steel Foam Sandwiches

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Processing and Properties of Steel Foam Sandwiches

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Processing and properties of steel

foam sandwiches

L.P.Lefebvre1_{, M.Gauthier}1_{, E.Baril}1_{, B.Voizelle}2 1_{National Research Council Canada/Industrial Materials Institute}

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National Research

Council Canada

Institutes

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Scope

– Introduction – Process

– Results

• Part 1: Effect of density and composition on the compressive properties of the foams

• Part 2: Effect of the foam and face sheet properties on the properties of steel foam sandwiches

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Steel foams

sandwiches

• Lightweight structures

• Improved rigidity

• Energy absorption (i.e. improved crashworthiness) • Vibration absorption…

• Challenge:

– To produce highly porous structures at low cost – Capability to produce large panels

• Simple process

• Inexpensive starting materials • PM Avoid densification steps

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IMI process

L. P.Lefebvre, Y. Thomas, Method of Making Open Cell Material, US Patent 6,660,224 B2, Dec. 9, 2003.

• No compaction required • Open porosity • Porosity 50-93% Ceramic Bronze Titanium Nickel Copper Steel Iron Debinding

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Material

• Diffusion bonded steel premixes (FD-0400) • Screened -325 mesh

• 9.5%Ni, 5%Cu, 0.5%Mo and 0.15%Mn

• Admixed with phenolic resin and foaming agent. • Foaming @ 110°C

• Debinding at 500°C in air • Sintering at 1200°C in H2

• Cementation treatment: 30 min at 900°C using cracked Vapocarb fluid (Lindberg), cooled to RT in Ar

• Tempering 800°C/H₂

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Structure, dimensions

and density along

processing steps

Foamed  Debinded 20.2% Debinded  Sintered 25.5% Foamed  Sintered 40.5%

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Effect of composition:

Compression

x,y

E =d /d

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Compressive properties

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Compressive

properties: Foams

Energy absorbed at

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Effect of

composition: Energy

Before cementation After cementation

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Sandwich panels

Foaming Debinding Sintering/ Heat Treatment

Finishing

Connector plates:

• Help handling the foam during processing • Perforation helps binder removal

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Sandwich panels and

Profiles

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Composite

sandwiches

Steel foam

Steel sheet Twintex

Twintex:

PP/Glass roving (60%) Density: 1.89 g/cm3

Tensile strength: 960 MPa Tensile modulus: 38.5 GPa Flexural strength: 860 MPa Flexural modulus: 37.5 GPa

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Density

Steel Foam Sandw ich ich/Tw intex D en s it y (g/c m 3 ) 0 2 4 6 8 10

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Compressive

properties

Foam vs sandwich

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Mechanical properties

FD-0400 (cemented)

ich 2 g /cm3 0.71 g/cm 3 m 2 g /cm3* x, y ( M Pa) 0 5 10 15 20 25 30 * Extrapolated ich 2 g/ cm3 0.71 g/cm 3 m 2 g/ cm3* M odulus ( M Pa) 0 200 400 600 800

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Compressive

properties:

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Flexion

3 points bending

Foam density: 0.66 g/cm3 Sandwich density: 2.04 g/cm3

Density with composite: 2.17 g/cm3 Span: 140 mm

Length: 190 mm Width: 33 mm Thickness: 10 mm

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Conclusion…

• Simple process to produce iron-based foams and foam sandwiches

• Foam density around 0.65g/cm3 _{(i.e. porosity}

around 93%)

• Pins contribute to increase the modulus, the yield strength and the energy at densification.

• Properties of the core and face sheets have an impact on the compressive and flexural properties

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Future work

• Optimization of the foam composition and

microstructure to further improve the mechanical properties

• Evaluation of different face sheets to improve the specific properties of the materials

• Process optimization, scale-up • Validation in applications

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