Manufacturing of Expanded Glass Reinforced Syntactic Foam Metal and Investigation of Microstructure and Mechanical Properties

Abstract

In this study Syntactic Foam Metals (SFM), which are a developed structure of foam metals, is manufactured and analyzed. SFM are materials with porous structure formed by using hollow ceramic spheres. SFM have a closed cell structure and is a kind of composite. As matrix metal 7075 aluminum and as reinforced material expanded glass is used. Advantages of SFM is lightness, high compression strength, vibration and shock absorbing characteristics. In this study as manufacturing method, liquid infiltration is used. By this method, the mold and spheres are heated in a furnace up to 800 ˚C. Later glass spheres and mold are taken out from the furnace, glass spheres and molten aluminum are placed inside the mold cavity and a casting pressure of 6,3 kPa is applied. Afterwards inner structure was analyzed and concluded that glass spheres were not broken and were homogenous dispersed inside the specimen. Arshimed principle was used to determine the density of 25 mm diameter and 33 mm height cylindrical specimens. The density was 1,33-1,68 g/cm3. Porosity is calculated between 53,3-57,2%. Compression tests were performed to analyze mechanical performance and a typical plateau stress was observed as seen by different SFM’s. The plateau stress value was 22-42 MPa and shock absorbing energy 12-22 MJ/m3. These values are accommodating with the values in the literature. Also linear relation was correlated between the plateau stress value and shock absorbing energy.

Keywords

• Syntactic Foam Metal
• Expanded glass sphere
• Aluminum
• Microstructure
• Mechanical properties

GENLEŞTİRİLMİŞ CAM TAKVİYELİ SİNTAKTİK KÖPÜK METALİN ÜRETİMİ, İÇYAPI VE MEKANİK ÖZELLİKLERİN İNCELENMESİ

Öz

Bu çalışmada köpük metallerin geliştirilmiş bir şekli olan Sintaktik Köpük Metal (SKM) üretilmiş ve analiz edilmiştir. SKM’de yapı içindeki gözeneklilik, içi boş seramik küreler yardımıyla oluşturulmaktadır. SKM kapalı hücre yapısına sahiptir. SKM’lerin avantajları; hafiflik, yüksek basma dayanımı, titreşim sönümleme ve enerji absorbe etme kabiliyetidir. Kompozit bir malzeme olan SKM’in üretiminde matris malzemesi olarak 7075 alüminyum, takviye malzemesi olarak da içi gözenekli yapıya sahip genleştirilmiş cam küre kullanılmıştır. Çalışmamızda SKM sıvı infiltrasyon yöntemi ile üretilmiştir. Bu üretim yönteminde kalıp ve küreler, 800 ˚C sıcaklıktaki fırında bekletildikten sonra fırından çıkarılmış ve kalıp boşluğuna cam küre ve ergimiş alüminyumun yerleştirilmesinden sonra 6,3 kPa’lık döküm basıncı uygulanmıştır. Üretilmiş olan SKM’lerin içyapısı analiz edilmiş, cam kürelerin yapı içinde homojen bir şekilde dağıldığı ve kürelerin kırılmadığı tespit edilmiştir. 25 mm çapında ve 30-33 mm yüksekliğe sahip silindirik SKM numunelerin yoğunluk değerleri Arşimed prensibi kullanılarak 1,33-1,68 g/cm3 olarak ölçülmüştür. Gözeneklilik değerleri ise %53,3-57,2 olarak hesaplanmıştır. Mekanik testler için basma deneyleri gerçekleştirilmiş ve SKM’lerde görülen tipik plato eğrileri tespit edilmiştir. Plato dayanım değerleri 22-42 MPa, darbe sönümleme enerji değerlerinin ise 12-22 MJ/m3 arasında olduğu görülmüştür. Bu değerler literatürde karşılaşılan verilerle uyumlu olduğu ve plato dayanım değeri ile enerji absorbe etme değerleri arasında doğrusal bir ilişkinin var olduğu tespit edilmiştir.

Anahtar Kelimeler

• Sintaktik Köpük Metal
• Genleştirilmiş cam küre
• Alüminyum
• İçyapı
• Mekanik özellikler

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