PhD of Industrial Engineering
Research Activity on Energy
Metal Foams For Energy Applications
S.K. Balijepalli, G. Barbieri, G. Costanza, S. Kaciulis, G. Lapi, R. Montanari, M.E. Tata
Metal Foams Applications
Metal foams can be used for filtration and
separation processes. For exaple the particulate
emissions generated from a side-mounted 2.4 L
gasoline direct injection engime were evaluated
using a metal foam-type gasoline particulate filter
and the number of sub-23 nm particles formed was
reduced with 97% efficiency.
Kim et. al., Journal of Aerosol Science, vol. 57 p.1, 2013.
They can be used in thermal energy storage device
in thermal energy applications in areas such as
energy afficients buildings and solar thermal power
plants. In the solid/liquid phase change process the
paraffin wax RT58 is used as phase change material
and the addiction of metal-foam can increase the
overall heat transfer rate by 3 to 10 times,
depending on the metal foam structures and
materials.
Lu et.al., Solar Energy, vol.84 p.1402, 2010.
Metal Foams Applications
Thermal transport in metal foams has received growing
attention in both academic research and industrial
applications. High porosity, open-celled metal foams
have emerged as one of the most promising materials
for thermal management applications where a large
amount of heat needs to be transported over a small
volume. The motivation is attributed to the high
surface area to volume ratio as well as enhanced flow
mixing due to the tortuosity of metal foams.
Metal Foams Applications
A new technology for continuous and high-efficiency alkali-catalyzed biodiesel
synthesis using a metal foam reactor combined with a passive mixer has been
developed. Metal foam reactors are developed to improve conversion efficiency and
biodiesel yield per reactor with a homogeneous alkali-catalyzed biodiesel synthesis.
Compared with conventional stirred reactors, the time for high methyl ester conversion
can be shortened remarkably by the use of metal foam reactors.
The results indicate the great potential of metal foam reactors in small-fuel biodiesel
processing plants for distributive applications.
Lead – Foams Electrodes
“Experiences of Lead-Foam Production by Several Processing Routes”
“Development of lead-foam electrodes for high-efficient batteries recycling scraps”
M.E. Tata, G. Costanza
Lead – foams could be used as electrodes in batteries instead of Pb bulk. Two techniques
have been used to manufacturing Pb foams: replication process (RP) and sintering and
dissolution process (SDP). The electrodes were immersed in sulfuric acid 31% and
subjected to charge. After four hours the accumulator had a voltage of 2.2 V. A 3W-lamp,
powered by the electrodes during discharge, remained alight for 30 minutes. The goal of
this work is to produce microporous electrodes that can replace the standard ones, with
improved performance and a weight reduction.
Aluminium Foam Sandwiches
Aluminium Foams, particularly Aluminium Foam Sandwiches
(AFS), offer a great potential for applications in the automotive
industry. AFS are light weight, energy absorbing and
incombustible and have good sound absorbing properties.
Aluminium Foam Sandwiches are composites comprising an aluminium alloy foam core
and two dense metallic sheets firmly attached to the core.
AFS Properties
• Light weight
• Energy absorbing
• Incombustible
• Sound absorbing
AFS Applications
Regarding their promising mechanical properties
the aluminium foams can be used in car/vehicle
industry. The breakthrough happened already in
2006: for a structural item of Audi Q7 car
featured by energy absorption. In the Ferrari F430
To offset the loss of the roof, the Spider's chassis
has been significantly reinforced. The sill
members have been strengthened with extremely
light, rigid aluminium foam inserts where they
connect to the rear B-pillar chassis members.
Teupen (Gronau, Germay) has
developed a novel concept for the
support structure of a telescope arm
lifting a working platform. Using AFS
the goal was to increase the current
working height of 20m to 25m while
keeping the total weight below 3500
Kg.
AFS Production
One way to manufacture AFS was developed at the FraunhoferInstitute. A three layer composite comprising a foamable
aluminium alloy sheet as a core layer and two face sheets on
both sedes is made by extrusion or powder rolling and various
subsequent
rolling
operations, after which
the core layer of the panel
is expanded by heating to
the foaming temperature.
A pure metallic bonding is
maintained that is less
heat sensitive than an
adhesive and can be used
to manufacture heat
resistant non-inflammable
structures.
Effects of Powder mix composition
“Effect of Powder mix composition on Al foam morphology”
G. Gusmano, R. Montanari et.al.
The effect of mix composition on foam morphology has been examinated by image
analysis carried out on metallographic sections of Al foams prepared by powder
metallurgy. Samples have been prepared by using SiC particles with different mean size
and different amounts of TiH2. SiC particles distribution on the internal walls of the
bubbles has been investigated by SEM observations, which
evidenced also the presence of particles of another phase, identified
as Ti3Al by EDS.
Artificial Neural Networks
“Effect of Powder mix composition on Al foam morphology”
G. Gusmano, R. Montanari et.al.
Experimental data discuss in the previous work have been used
for training two multi-layer feedforward artificial neural
networks. The model represent useful tools for predicting
morphologic features of foams for any given mix composition in
the training range.
Finite Element Model (FEM)
“Numerical Simulation of Open-Cell Aluminium Foams Under Compression”
F. Quadrini, D. Bellisario, D. Ferrari, L. Santo, A. Santarsiero
The numerical simulation of the compression behavior of open-cell aluminium foams is a
way to extract material prperty information. A bilinear isotropic model was implemented
for the alloy base material whereas a parametric approach was used to build the finite
element model of the foam structure. Compression tests were performed on commercial
foams with different pore size and density, and the results of lower density foam were used
for the model validation. Numerical results show a good
agreement with
experimental data
in terms of foam
deformation
under
compression and
required loads.
Sheet/Core metallic bonding
MiSE – ENEA
Ricerca di Sistema Elettrico
Fe
Al
“Risparmio di energia nel settore dei trasporti”
Has been studied the possibility of establishing a
metallurgical bond between steel sheets and Al alloy core.
The EDS analysis show the interdiffusion of Al and Fe
through an interface of about 40 microns.
EDS
signal
for Al.
EDS
signal
for Fe.
Sheet/Core metallic bonding
Has been studied the possibility to reinforce
extruded AA6060 with AlSi10 foam. The
results show a good metallurgical bond and a
lack of homogeneity in the foam due to an
incorrect calibration of the temperature in the
oven.
Extruded profile
in AA6060
AlSi10 Foam
Hot pressing and extrusion.
Automatic Foaming Oven.
PSR2
Estruso 20 X 30
X 400 mm
Parte finale collassata
PSR1
RX digitali
PSR2
Grazie per l’attenzione