Metal Foams: Functional Properties

Dr Russell Goodall
Department of Materials Science & Engineering The University of Sheffield
Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

This course
1) Introduction Sheffield, metal foam and how it relates to the processing and properties of metallic components generally. 2) Processing Processing of porous metals and further processing: shaping, joining, recycling and cost aspects. 3) Characterisation Important parameters and methods for characterisation 4) Structural Properties Mechanical behaviour of porous metals, and methods that allow prediction. 5) Functional Properties Other properties of porous metals. 6) Applications General applications of metal foams 7) Case Studies I: lightweight structures; II: heat transfer; III: Bio-implants

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Expansion

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Expansion Definition

The dimensional change with temperature Coefficient of Thermal Expansion (CTE):

= L/L0 . 1/T

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Expansion in Foams

For a random foam, CTE is exactly the same as the dense solid Gas in a closed cell foam can exert some effect, but this is normally negligible

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Expansion in Lattices

For a random foam, CTE is exactly the same as the dense solid Lattices can be designed to be different if we can combine 2 materials with different CTEs Can be zero or negative

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Conduction Properties

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Conductivity Definition / Equations

Ohms / Fouriers Law Essentially: Flux

Potential Conductivity

Can be I = V kelect Or Q = C T ktherm

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Conduction
1st limit Foam with a few pores Use theory of isolated spheres (Torquato)

3 3 2 3 kf = k m 1 Vm + Vm + O(Vm ) 2 4
2nd limit Foam with many pores Use theory of randomly oriented struts (Lemlich)

k mVm kf = 3
Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Conduction
Mean field / differential effective medium (DEM) techniques extend isolated pore equations to higher values DEM Spheres

DEM Ellipsoids

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Conduction
Different models suit different foams Closed pore type Duocel / Incofoam type

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Conduction
Conduction through solid identical to electrical conductivity (the mechanism is the same) Other mechanisms are possible: Conduction in gas Convection Radiation

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Conduction Gas Conduction

Conductivity of air is very low: Air K = 0.024 W / m K Cu K = 401 W / m K Al K = 250 W / m K Water K = 0.58 W / m K In most situations, conduction through the gas phase is ignored
Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Conduction - Convection

Convection could be significant Tests have been made of conduction in horizontal insulator samples, heated from above and below Results show negligible contribution if pores are < 4mm diameter Likely to be even less in metal foams

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Thermal Conduction - Radiation

Governed by the Stefan-Boltzmann law: Q = T4 Heat transport by radiation increases with: Temperature Pore Size

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Permeability

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Permeability Definition / Equations

Special property of porous solids Permeability is the resistance to fluid flow
For normal engineering situations, Darcys law applies:

where P = fluid pressure, x = distance along fluid flow direction, = fluid viscosity, = fluid density, 0 = fluid velocity, K = permeability and C = form coefficient

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Permeability Definition / Equations

Low 0: Viscosity dominated flow (K)

High 0: Inertia dominated flow (C)

At low velocities, can rewrite Darcys law as:

Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Permeability Measurements
Need to record P, 0 measure x and Should be done for several values of P Linearity confirms correct regime
Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico

Permeability Prediction
Some simple models exist e.g. that of Despois & Mortensen*, based on the idea of the constrictions caused by windows, with the size calculated from interpenetrating spheres

where r = pore radius, = pore volume fraction, 0 = packing density of spheres (=0.64)
*J F Despois & A Mortensen, Acta Materialia 53 (2005) 1381-1388
Escuela de Ciencia e Ingeniera de Materiales 2011, UNAM, Mxico