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Research Papers

A Study on the Design and Mechanical Adhesion of Polymer Foam-Metal Joints

[+] Author and Article Information
Ahsan Ahmed, Atef Fahim

Department of Mechanical Engineering, University of Ottawa, Ottawa, ON, Canada K1N 6N5

Hani Naguib

Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, ON, Canada M5S 3G8

J. Eng. Mater. Technol 130(3), 031011 (Jun 11, 2008) (7 pages) doi:10.1115/1.2931149 History: Received May 17, 2007; Revised February 09, 2008; Published June 11, 2008

The design of metal-polymer foam adhesion and load transfer characteristics is carried out in this research work. The metal inserts are used as the load transfer component, while the foam is used as the structural element of the system. The inserts are embedded in the foam during the foaming process. Flexural testing was conducted on different metal foam configurations to establish the typical interaction trends. The load-deflection response and the mode of failure of the structure were documented. Moduli of elasticity of the system for various geometries and embedded lengths were evaluated, and behavior patterns were gleaned. Rectangular, circular, and triangular (taper-/wedgelike) inserts were used. Results show that simple taper inserts embedded in foam slabs perform better than the other shapes. Finite element analyses of the interaction under different loads were carried out. The modeling results coincided with the experimental ones hence validating the model.

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Copyright © 2008 by American Society of Mechanical Engineers
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References

Figures

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Figure 3

Photographs showing the nature of the fracture of the composite structure with rectangular inserts: (a) foam fracture for long insert lengths; (b) bonding failure for short insert length

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Figure 4

Load deflection curves for foam slabs with and without rectangular inserts

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Figure 5

Trend line of the increase in modulus of elasticity E due to the increase in length of rectangular inserts. E for simple foam without insert: 0.0451GPa

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Figure 6

Different bonding failure stages of slabs with cylindrical insert: (a) initial; (b) final

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Figure 7

Load-deflection curves for slabs with and without cylindrical inserts

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Figure 8

Trend line of the increase in modulus of elasticity E due to the increase in length of cylindrical inserts. E for simple foam without insert: 0.0451GPa

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Figure 9

Load-deflection curves for slabs with and without taper inserts

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Figure 10

Trend line of increase in modulus of elasticity E due to the increase in length of taper inserts. E for simple foam without insert: 0.0451GPa

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Figure 11

Load-deflection curves from ANSYS for the (a) rectangular, (b) cylindrical, and (c) taper geometries

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Figure 12

Load-deflection curves from ANSYS for the reduced span length model for (a) rectangular, (b) cylindrical, and (c) taper inserts

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Figure 13

Load-deflection curves from ANSYS for the reduced height models for (a) rectangular, (b) cylindrical, and (c) taper insert

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Figure 2

Schematic diagram showing the modified three-point bending setup (load is applied to the foam while attachments screwed to the embedded inserts rested on supports)

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Figure 1

Photographs of the PU foam slabs with rectangular and cylindrical inserts

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