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Open AccessArticle

Structure and Compressive Properties of Invar-Cenosphere Syntactic Foams

by Dung Luong 1,*,†, Dirk Lehmhus 2,3,†, Nikhil Gupta 1,†, Joerg Weise 4 and Mohamed Bayoumi 5
Composite Materials and Mechanics Laboratory, Mechanical and Aerospace Engineering Department, Tandon School of Engineering, New York University, Brooklyn, NY 11201, USA
ISIS Sensorial Materials Scientific Centre, University of Bremen, Bremen D-28359, Germany
MAPEX Center for Materials and Processes, University of Bremen, Bremen D-28359, Germany
Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), Bremen D-28359, Germany
Department of Mechanical Engineering, Al-Azhar University, Cairo 11651, Egypt
Author to whom correspondence should be addressed.
These authors contributed equally to this work.
Academic Editor: Sven De Schampheleire
Materials 2016, 9(2), 115;
Received: 25 December 2015 / Revised: 2 February 2016 / Accepted: 5 February 2016 / Published: 18 February 2016
(This article belongs to the Special Issue Metal Foams: Synthesis, Characterization and Applications)
The present study investigates the mechanical performance of syntactic foams produced by means of the metal powder injection molding process having an Invar (FeNi36) matrix and including cenospheres as hollow particles at weight fractions (wt.%) of 5 and 10, respectively, corresponding to approximately 41.6 and 60.0 vol.% in relation to the metal content and at 0.6 g/cm3 hollow particle density. The synthesis process results in survival of cenospheres and provides low density syntactic foams. The microstructure of the materials is investigated as well as the mechanical performance under quasi-static and high strain rate compressive loads. The compressive stress-strain curves of syntactic foams reveal a continuous strain hardening behavior in the plastic region, followed by a densification region. The results reveal a strain rate sensitivity in cenosphere-based Invar matrix syntactic foams. Differences in properties between cenosphere- and glass microsphere-based materials are discussed in relation to the findings of microstructural investigations. Cenospheres present a viable choice as filler material in iron-based syntactic foams due to their higher thermal stability compared to glass microspheres. View Full-Text
Keywords: syntactic foams; metal foams; metal matrix composites; high strain rate; strain rate sensitivity; split-Hopkinson pressure bar syntactic foams; metal foams; metal matrix composites; high strain rate; strain rate sensitivity; split-Hopkinson pressure bar
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Luong, D.; Lehmhus, D.; Gupta, N.; Weise, J.; Bayoumi, M. Structure and Compressive Properties of Invar-Cenosphere Syntactic Foams. Materials 2016, 9, 115.

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