泡沫铝在抗恶劣环境计算机机箱中的应用研究

以传统的减振器减振机箱为基础,对新型的泡沫铝材料进行研究设计出泡沫铝减振机箱.基于随机振动理论,利用有限元法对减振器减振机箱和泡沫铝减振机箱开展随机振动分析,将其力学性能进行了对比得出泡沫铝减振机箱其加速度均方根值减小量达39.6%.新型泡沫铝减振机箱比减振器减振机箱可更好的降低外界对电子设备的动态影响,提高了设备的可靠性.     

泡沫铝夹芯结构高速移动工作台研究

为满足高速、超高速加工对机床移动工作台轻质高动态性能的要求,设计了以铸铁为面板、泡沫铝为芯体材料的夹芯结构移动工作台,并利用有限元分析软件研究了该工作台的静、动态特性。研究结果表明与传统铸铁材料工作台相比,泡沫铝夹芯结构移动工作台具有质量轻、固有频率高、谐振响应幅值低等特点,从而证明了泡沫铝夹芯结构工作台在高速、超高速加工中应用的可行性和优越性。     

An investigation on the fatigue behavior of DCB specimen bonded with aluminum foam at Mode III

Aluminum foam with its excellent physical and mechanical characteristics is a lightweight metallic material used with good quality in vehicle bumpers, internal shock absorbers on planes, as materials for vessel joints etc. On the contrary, when aluminum foam is used without sufficient investigation, there is the likelihood of damage or destruction of the machine or mechanical structure, and in extreme case it may cause to human casualties. This study aims to analyze the characteristics of adhesive structures with aluminum foam for the closed-type aluminum foam used primarily as shock absorbers. The fatigue analyses of the DCB test specimens at mode III with aluminum foam are verified through a fatigue experiment. As the analysis results, test specimen models with the thicknesses (t) of 35 mm, 45 mm and 55 mm showed the peak load occurrence approximately after the progress from 0 to 50 cycles. And afterwards the load gradually decreased as the cycles increased. The peak loads for each DCB test specimens were ±0.80 kN for the specimen thickness(t) of 35 mm, ±0.98 kN for the specimen thickness(t) of 45 mm and ±1.18 kN for the specimen thickness(t) of 55 mm. It is also shown that the peak load occurring on the specimen increased as specimen thickness increased. These study results are compared with the specimen thickness of 35 mm model as the basis. When the specimen thickness is increased as much as 10 mm, the peak load is increased approximately 1.25 times. When the specimen thickness is also increased as much as 20 mm, the peak load is increased 1.5 times. The analysis data and the real experiment data showed similar results each other. Therefore, it can be thought that the analysis data is applicable in real field. And it is estimated that the mechanical characteristics of the DCB test specimen at mode III during the fatigue load conditions can be systematically and efficiently analyzed.     

Blast attenuation in Cymat foam core sacrificial claddings

The mechanism of air blast attenuation in a sacrificial cladding comprising a steel cover plate and a foam core is examined applying an analytical and numerical analysis. For the range of the analysed pressure pulses, the maximum magnitudes of the induced compaction velocities were usually smaller than the acoustic wave speed in the foam material and caused a non-uniform foam density distribution along the compacted region. A significant density decay measured from the proximal end of the cladding was observed within the compacted foam zone due to a rapid reduction of the compaction velocity. An analytical model was developed to reveal the characteristic features of the foam compaction under a moderate velocity impact. It was shown that waves of strong discontinuity, such as shock waves resulting from an overtaking of the stress increments cannot be initiated in the foam. It was revealed, however, that the stress wave propagation in the form of an unloading plastic wave has a significant dynamic effect on the foam compaction and energy absorption. It was concluded that a quasi-static approach cannot be used to accurately estimate the absorbed energy, at least for partially compacted foam. The predictions of the proposed analytical model are compared with other published analytical models for a foam compaction under a high and low velocity impact and with the results from the numerical simulations of the foam deformation in a finite thickness sacrificial cladding subjected to a blast loading. The numerical model was verified with blast loading tests of 50 mm thick Cymat foam claddings having a density of 253 kg/m³. The influence of the cladding characteristics on the reflected stress from the stationary end of the cladding was also analysed when using the proposed model for foam compaction.     

粉煤灰漂珠/聚氨酯复合泡沫铝材料压缩性能与本构关系研究

采用压力渗透法制备出了铝基复合泡沫材料,填充材料是以粉煤灰漂珠为主要组分、硬质聚氨酯泡沫为粘结剂的复合泡沫材料.通过准静态实验和分离式霍普金森压杆(Split Hopkinson pressure bar,SHPB)动态压缩的方法研究了复合泡沫铝的压缩力学响应,然后建立了动态本构关系.研究表明,复合泡沫铝的压缩应力-应变曲线与其它泡沫材料的应力-应变曲线类似,文中的两种铝基复合泡沫具有应变率效应,复合泡沫铝较密度相近未填充前的泡沫铝基具有更高的压缩强度与能量吸收能力.但由于漂珠尺寸的不同,导致两种复合泡沫铝的动态压缩结果不尽相同,且小颗粒复合泡沫铝在动态冲击下吸能效果最好.在本研究实验的应变率和密度范围内,本文建立的本构模型曲线与实验曲线吻合较好.     

粉煤灰漂珠/聚氨酯复合泡沫铝材料压缩性能与本构关系研究

采用压力渗透法制备出了铝基复合泡沫材料,填充材料是以粉煤灰漂珠为主要组分、硬质聚氨酯泡沫为粘结剂的复合泡沫材料.通过准静态实验和分离式霍普金森压杆(Split Hopkinson pressure bar,SHPB)动态压缩的方法研究了复合泡沫铝的压缩力学响应,然后建立了动态本构关系.研究表明,复合泡沫铝的压缩应力-应变曲线与其它泡沫材料的应力-应变曲线类似,文中的两种铝基复合泡沫具有应变率效应,复合泡沫铝较密度相近未填充前的泡沫铝基具有更高的压缩强度与能量吸收能力.但由于漂珠尺寸的不同,导致两种复合泡沫铝的动态压缩结果不尽相同,且小颗粒复合泡沫铝在动态冲击下吸能效果最好.在本研究实验的应变率和密度范围内,本文建立的本构模型曲线与实验曲线吻合较好.     

碳化硅增强泡沫铝层合圆管的制备及力学性能研究

用熔体发泡法制备了碳化硅颗粒增强泡沫铝样品，分析了碳化硅增强泡沫铝在准静态压缩条件下的变形行为。用不锈钢圆管为面板，碳化硅颗粒增强泡沫铝为夹芯制备层合圆管，研究了层合圆管在准静态压缩条件下的变形行为和能量吸收性能。研究表明：碳化硅颗粒增强泡沫铝的屈服强度在5～12MPa之间，对泡沫铝材料的力学性能有明显的增强作用；层合圆管在保持泡沫铝轻质、高吸能效率的同时，大幅度提高了吸能能力；碳化硅增强泡沫铝层合圆管的压缩屈服应力达到45MPa，平台应力达到40MPa，具有优良的吸能性能。     

Thermal characteristics of graphite foam thermosyphon for electronics cooling

Graphite foams consist of a network of interconnected graphite ligaments and are beginning to be applied to thermal management of electronics. The thermal conductivity of the bulk graphite foam is similar to aluminum, but graphite foam has one-fifth the density of aluminum. This combination of high thermal conductivity and low density results in a specific thermal conductivity about five times higher than that of aluminum, allowing heat to rapidly propagate into the foam. This heat is spread out over the very large surface area within the foam, enabling large amounts of energy to be transferred with relatively low temperature difference. For the purpose of graphite foam thermosyphon design in electronics cooling, various effects such as graphite foam geometry, sub-cooling, working fluid effect, and liquid level were investigated in this study. The best thermal performance was achieved with the large graphite foam, working fluid with the lowest boiling point, a liquid level with the exact height of the graphite foam, and at the lowest sub-cooling temperature.     

Dynamic indentation and penetration of aluminium foams

Failure of metal foams caused by dynamic indentation and penetration is very common in practice, such as light-weight structural sandwich panels, packing materials and energy absorbing devices. Rational application of these materials requires a sound understanding of deformation and energy absorption mechanisms of the aluminium foams as well as the effect of impact velocity. In this study, following experimental investigations into compression, tension, sharing and indentation of CYMAT aluminium foams of various densities, a finite element (FE) analysis using ABAQUS is conducted for dynamic indentation process of aluminium foams under a rigid, flat-headed indenter. Two methods of applying impact velocities are considered: the indenter is pushed into the foam at a constant velocity through the whole process or with an initial velocity which then decreases with indentation. Two energy dissipation mechanisms are considered: compression of the foam ahead of the indenter and fracture along the indenter edge. Effect of impact velocity is noted on the size of a localized deformation and the total energy absorbed. A plastic structural shock theory developed by previous researchers is applied to calculate the resistance force with indentation depth during indentation process and fair agreement is obtained between the analytical and numerical results.     

用铝粉作增粘剂制备泡沫铝

采用熔体发泡法制备了孔结构均匀、孔隙率高的泡沫铝材料,系统研究了铝粉(增粘剂)含量、增粘搅拌时间、保温时间和发泡剂的含量对孔隙率和孔结构的影响。对铝粉在铝熔体中的增粘机理以及在发泡过程中对气泡的稳定作用进行了讨论。结果表明:加入质量分数5％铝粉,搅拌时间7 min,发泡剂TiH2质量分数1．5％,保温5 min的条件下,可以得到孔结构均匀、孔隙率约75％的泡沫铝硅合金材料。     

Plasma-accelerated flyer-plates for equation of state studies

We report on a new technique to accelerate flyer-plates to high velocities (～5 km∕s). In this work, a strong shock is created through direct laser ablation of a thin polyimide foil. Subsequent shock breakout of that foil results in the generation of a plasma characterized by a smoothly increasing density gradient and a strong forward momentum. Stagnation of this plasma onto an aluminum foil and the resultant momentum transfer accelerates a thin aluminum flyer-plate. The aluminum flyer-plate is then accelerated to a peak velocity of ～5 km∕s before impact with a transparent lithium fluoride (LiF) window. Simulations of the stagnating plasma ramp compression and wave reverberations within the flyer-plate suggest that the temperature at the flyer-plate impact surface is elevated by less than 50 °C. Optical velocimetry is used to measure the flyer-plate velocity and impact conditions enabling the shocked refractive index of LiF to be determined. The results presented here are in agreement with conventional flyer-plate measurements validating the use of plasma-accelerated flyer-plates for equation of state and impact studies.     

A new shell casting process based on expendable pattern with vacuum and low-pressure casting for aluminum and magnesium alloys

A new shell casting process, with the adoption of the foam pattern of lost foam casting (LFC) as prototype and the combination of the thin shell fabrication technology of investment casting and vacuum and low-pressure casting process, was proposed for manufacturing complicated and thin-walled aluminum and magnesium alloy precision castings. Loose-sand uniting vacuum was used in the new process to further reinforce the thin shell, and the new process proves to be a process with simple process, low cost, and high thin shell strength. Because the molten metal filling and solidification are completed under air pressure and vacuum level, the filling capability and feeding capacity of the molten metal are greatly improved, and the castings become denser. This paper mainly investigated the fabrication technology of thin shell based on foam pattern prototype, the removing foam and roasting shell process and vacuum and low-pressure casting process. The few-layer compound thin shell of silica sol–sodium silicate was adopted for the new process. Removing foam pattern was carried out at 250°C for 30 min, and the shell was roasted at 800°C for 1 h. Combined with the vacuum and low-pressure casting process, this new shell casting process has successfully produced thin wall and complex aluminum and magnesium alloy parts with high quality. In addition, comparisons in terms of filling ability, microstructure, mechanical properties, porosity, and surface roughness among this new shell casting, gravity casting, and LFC were also made to show the characterization of this new shell casting process.     

液压减振器橡胶气带性能测试与分析

发泡橡胶具有较好的耐热老化性、耐油性和耐压缩永久变形性能,在液压减振器储油腔中采用发泡橡胶气带替代气腔,是解决减振器气穴现象和油液乳化现象的有效方法。发泡橡胶特性对减振器阻尼作用有很大的影响,通过发泡橡胶在液压油内压缩实验,用回归分析方法得到其压力-体积变化规律,进一步利用 AMESim软件完成对采用橡胶气带减振器的仿真分析。减振器测试结果表明,发泡橡胶的压力-体积变化规律较好的反映了气带在减振器中的工作情况,对液压减振器用发泡橡胶气带的设计有一定的指导意义。     

闭孔泡沫纯铝的导热性能

采用隔热测试仪研究了闭孔泡沫纯铝的孔隙率和孔径对其导热性能(导热系数)的影响.结果表明:闭孔泡沫纯铝的导热性能受传导、对流、辐射三者的综合影响;孔隙率为83.2%～91.0%的闭孔泡沫纯铝的导热系数随孔隙率的增大而减小,而孔径对导热系数的影响没有一定规律;在孔隙率为83.2%～91.0%、孔径为2.5～5.3 mm时,闭孔泡沫纯铝的导热系数在常温下为0.297～0.752 W/(m·K).     

Effect of an ultralight metal filler on the bending collapse behavior of thin-walled prismatic columns

The effect of low-density metal filler, such as aluminum foam or honeycomb, is studied on the bending collapse resistance of thin–walled prismatic columns. A combination of analytical and numerical results is used to predict the initial and post collapse response of empty and filled columns. Closed-formed solutions for the bending-rotation characteristics are constructed in terms of the geometrical parameters and the filler strength. The low-density metal core retards sectional collapse of the thin-wall column, and increases bending resistance for the same rotation angle. Numerical simulations show that, in terms of achieving the highest energy absorption to weight ratio, columns with aluminum honeycomb or foam core are preferable to thickening the column wall. Moreover, the presence of adhesive improved the specific energy absorption significantly.     

Acceleration Measurement of Projectile High Velocity Penetrating Concrete Target and Acceleration Signal Analysis

A kind of novel on-boand memory acceleratian measure equipment, self-developed, had been employed in recent field test to obtain the acceleration of projectile penetrating many kinds of concrete target. At the same time, the aluminum foam with different density and pore-diameters had been utilized to protect cirruit modules. Fur-thermore, with the theoretical analysis, computer simulation and field test, the high frequency's impact on the tested acceleration of the projectile had been discussed; At last, the analysis on output signal tested the validity of test data.     

稀土对泡沫铝及泡沫铝合金耐腐蚀性能的影响

研究了稀土对泡沫铝及泡沫铝合金泡沫化和压缩性能的影响,讨论了稀土加入量和泡沫铝及泡沫铝合金耐腐蚀性能的关系。结果表明：稀土对铝合金泡沫化无异常影响;在泡沫铝和泡沫铝合金中添加适量稀土元素,可以提高泡沫铝和泡沫铝合金的耐腐蚀性能;相同腐蚀介质中,孔隙率高的泡沫铝合金腐蚀更严重;稀土对泡沫铝及其合金的力学性能影响不大。     

A continuum plasticity model for the constitutive and indentation behaviour of foamed metals

A yield surface is proposed that can be fitted to the plastic flow properties of a broad class of solids exhibiting plastic compressibility and different yield points in tension and compression. The yield surface is proposed to describe cellular solids, including foamed metals, and designed to be fitted to three experimental results: (1) the compressive stress–strain response (including densification), (2) the difference between the tensile and compressive yield points and (3) the degree of compressibility of the foam, as measured by the lateral expansion during a uniaxial stress compression test. The model is implemented using finite elements and used to study the effects of plastic compressibility on two problems: the compression of a doubly notched specimen and indentation by a spherical indenter. The model is then fitted to the properties of a typical closed cell aluminum foam and used to study indentation into a dense aluminum face sheet on a foam foundation. The dependence of the indentation load–displacement curve on the relevant material and geometric parameters is determined, and a single load–displacement relation is presented which approximates the behaviour of a wide range of practical designs. These results can be used to design against indentation failure of sandwich panels.     

铝泡沫填充薄壁结构耐撞可靠性优化设计

泡沫填充薄壁结构能有效地改善汽车薄壁吸能部件的耐撞性。为设计更轻与更有效的吸能结构,并满足汽车安全性设计要求,提出一种新颖的轻质铝泡沫填充双管薄壁结构,并对其耐撞性展开确定性最优化设计。但是,由于薄壁结构的厚度、屈服强度以及铝泡沫的密度等设计参数易受到仿真以及制造误差等不确定性因素的影响,导致确定性最优解收敛于约束边界,从而丢失了应有的使用可靠性要求。因此,提出基于Kriging近似模型与一阶可靠性分析方法的铝泡沫填充结构可靠性最优设计方法,并进一步开展基于参数不确定性的铝泡沫填充结构的耐撞性可靠性优化设计研究。优化结果显示,可靠性最优解不仅远离约束边界,而且较好地满足了铝泡沫填充结构的安全性与可靠性设计要求。     

On-Line Monitoring of PVC Foam Density Using Ultrasound Waves and Artificial Neural Networks

An artificial neural network (ANN) model was developed to monitor the density of rigid foam PVC on-line during the extrusion process using an ultrasound sensor mounted on the extruder die. Acoustic properties of the polymer melt, measured by multiple ultrasound echoes propagating through the polymer melt, were used to train a multilayer perceptron (MLP) artificial neural network to estimate the density of the extruded foam. The foam density was varied by varying the processing conditions, i.e. heating zones and screw speed, during the extrusion process. A high correlation was found to exist between the acoustic properties of the polymer melt and the foam density using a three-layer multilayer perceptron artificial neural network. .