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Aluminium foam sandwich (AFS) is a sandwich panel product which is made of two metallic dense face sheets and a metal foam core made of an aluminium alloy. AFS is an engineering structural material owing to its stiffness-to-mass ratio and energy absorption capacity ideal for application such as the shell of a high-speed train. [1]
Aluminized steel can be made using a variety of processes, cladding, hot dipping, galvanic coating, metallizing, and calorizing, but the most effective process is hot dipping. The process of hot dipping starts by cleaning the steel, then placing the steel in a bath of Al-11%Si at a temperature of 988K and shaken, then pulled out and air dried. [5]
The structural functionality of a sandwich panel is similar to the classic I-beam, where two face sheets primarily resist the in-plane and lateral bending loads (similar to flanges of an I- beam), while the core material mainly resists the shear loads (similar to the web of an I-beam). [1]
A load stretch wrapped with slip sheet on rotary arm stretch wrapper; slip sheets in foreground. A Slip sheet is “a corrugated, solid fiber, or plastic sheet onto which a unit load can be assembled. A protruding short panel can be grasped by the jaws of a pull-pack truck and the load pulled back onto the pull-pack platform.” [1]
Typical metals include Galvanized Steel, Galvalume, Aluminum, Copper, or Vinyl 9Which while not metal is included in many cases for its matching profiles). Corrugated galvanised iron is galvanised steel manufactured with wavy corrugations to resist lateral flexing and fitted with exposed fasteners. Widely used for low cost and durability.
CMF is made out of about 70% air and thus, weighs 70% less than an equal volume of the solid parent material. Composite metal foam is the strongest metal foam available with a 5-6 times greater strength to density ratio and over 7 times greater energy absorption capability than previous metal foams. [ 25 ]
When coated with a 50–100 nanometer layer of aluminum oxide, the material was able to withstand loads of as much as 280 megapascals, stronger than any other known material whose density was less than 1,000 kilograms per cubic metre (1,700 lb/cu yd), that of water.
(Glare1 can only consist of aluminum layers of 0.3 to 0.4 mm (0.012 to 0.016 in; 12 to 16 mils) thickness, though.) For example, Glare4B-4/3-0.4 is a Glare sheet with a Glare4 grade (using the B variant) where there are four aluminum layers and three glass fiber layers, and the thickness of each aluminum layer is 0.4 mm (0.016 in; 16 mils). [26]