Professional Documents
Culture Documents
The Synthesis, Compressive Properties, and Applications of Metal Matrix Syntactic Foams
The Synthesis, Compressive Properties, and Applications of Metal Matrix Syntactic Foams
Enhanced for the Web and incorporating those shells in ma- composites.3,4 Syntactic foams with
trix metals leads to porous materials over 50 vol.% porosity have been syn-
➠
Figure 5. (a)
Compressive
modulus of syn-
tactic foams (Es)
and (b) syntactic
foam modulus
normalized with
the modulus of
the matrix mate-
a b rial (Em) plotted
against density.
Figure 6. (a)
Compressive
yield strength of
syntactic foams
(sys) and (b) syn-
tactic foam yield
strength normal-
ized with the
yield strength of
the matrix mate-
a b rial (sym) plotted
against density.
foams. In the plastic stress, two dif- ergy absorption zones.43 Phenolic res- ume fraction and particle type. Metal
ferent regions are observed. Plastic ins filled with fly ash have been tested matrix syntactic foams are expected
stress of aluminum follows one trend for automotive break lining applica- to have better properties compared
line, whereas zinc and titanium follow tions.44 Metal matrix syntactic foams to open or closed-cell metallic foams
a different trend line. A wide distribu- can also find similar applications. since the former have controlled size
tion of strengths is observed for alu- Superior wear resistance of A356/fly and geometry of porosity and the ce-
minum alloy syntactic foams within ash45 and AA6061/fly ash46 compos- ramic shells contribute to stiffness and
a narrow density range. Plateau stress ites compared to the matrix alloy can strength. Some of the barriers to wide-
is an important property of syntactic be helpful in such applications. Ni-P/ spread use of metal matrix syntactic
foams because it determines the en- fly ash,47 Ni-Co/fly ash,47 and Al/fly foams can be overcome by the avail-
ergy absorption capability of the ma- ash48 composite coatings have been ability of:
terial. In general, plateau stress up to used for their wear-resistance proper- (1) Low-cost defect-free hollow mi-
250 MPa is observed in various types ties. These coatings reduced the wear crospheres in narrow size ranges,
of syntactic foams. of 5083 wrought aluminum alloy. including nanosize ranges
The compressive properties of metal Electromagnetic (EM) shielding (2) Mechanical and physical property
matrix syntactic foams are strain rate effects of 2024Al/fly ash composites data for hollow microspheres
sensitive.38,39 Evaluation of composite were found to be better than the ma- (3) Mechanical and physical prop-
properties at strain rates relevant to a trix alloy.49 In the frequency range of erty data for metal matrix syntac-
given application is required for cor- 1–600 MHz the EM shielding property tic foams, especially under high
rect materials selection. In addition, of 2024Al alloy was in the range −36 strain rates
in polymer matrix syntactic foams the to −46 dB while that of the composites (4) Processing methods enabling
failure mode is found to be strain rate was in the range of −40 to −102 dB. manufacture of large near-net-
sensitive,40 which should be evaluated These results show suitability of such shaped parts of syntactic foams
for metal matrix syntactic foams also. composites for lightweight electronic (5) Understanding of mechanisms of
packaging applications. Nickel coated deformation and fracture, and en-
applicationS
fly ash cenospheres have been stud- ergy absorption to develop quan-
Several present and potential ap- ied separately for EM shielding and titative relationships between
plications of syntactic foams are dis- microwave absorption applications.50 structure-processing-property and
cussed in the available literature. The Syntactic foams of these coated ceno- predictive capability to design mi-
damping capacity of 6061Al/fly ash spheres can be effective in electronic crostructures
syntactic foams is found to be much packaging applications. (6) Understanding of solidification
higher than that of the matrix alloy, structure formation in the matrix
concluSion
which is beneficial in automotive ap- in the presence of microballoons,
plications.41 Al-Si alloy/fly ash com- Most studies show substantially low and the influence of microbal-
posites also showed higher damping modulus of syntactic foams compared loons on grain size, dendrite size,
than the matrix alloy.42 Aluminum to the matrix alloy. The strength of micro-, and macrosegregation,
matrix syntactic foams have been ex- syntactic foams can be nearly equal and porosity in the matrix
plored for making automotive brake to that of the matrix. The plateau and (7) Understanding the reactions be-
rotors and differential covers.14 Stud- yield stress can be tailored over a wide tween the surfaces of microbal-
ies also suggest their use in crash en- range by selecting appropriate vol- loons and molten alloys and de-
Pradeep K. Rohatgi, Nikhil Gupta, Benjamin F. Schultz, and Dung D. Luong are TMS Members!
To read more about them, turn to page 14. To join TMS, visit www.tms.org/Society/Membership.aspx.