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Finite Element Modeling of Particle Distribution in Al/Powder Composite Sheets Processed by ARB for Manufacturing Aluminium Foams

Zarif Ahangaran, Saman | 2014

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 46543 (07)
  4. University: Sharif University of Technology
  5. Department: Materials science and Engineering
  6. Advisor(s): Akbarzade, Abbas
  7. Abstract:
  8. In this study closed cell aluminum foam was manufactured through accumulative roll bonding (ARB). In this method, aluminum AA1050 strip was used as the matrix and calcium carbonate was selected as blowing agent powder. The strips were roll-bonded with reduction of 50% during each pass. The produced composite was then subjected to different foaming conditions in order to achieve foams with maximum porosity. Subsequently, influences of content of the blowing agent, time, pressure, number of rolling passes and heating rate on the percentage of porosities were evaluated. In optimum condition quantity of the blowing agent, foaming temperature, holding time and number of ARB passes were equal to 1 wt. % of the metallic sheets, 700 °C, 7 minutes and 6 passes, respectively. The maximum porosity obtained under this condition was about 53%. A mathematical modelling for simulating the distribution of powder particle density in multi-layer composites was conducted to predict final properties of the composite and the foam. ABAQUS software was used to simulate the ARB process. 3D elasto-plastic analysis was performed and Drucker–Prager/cap plasticity model was used for modeling the powder particles between aluminum layers. Comparison of the calculated results and experimental data confirms the accuracy and validity of the proposed model. Due to the powder distribution on the sheet surface, increasing the number of ARB passes leads to decrease the surface density of calcium carbonate powder and consequently, it results in improved uniformity and porosity in the obtained foam
  9. Keywords:
  10. Simulation ; Cap Plasticity Model ; Accumulative Roll Bonding (ARB) ; Finite Element Method ; Drucker-Prager/Cap Plasticity Model ; Powder Density Distribution ; Foam Prosity

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