Title: TUNABLE LIGHTWEIGHT ENERGY ABSORBING FOAM CORE MATERIALS VIA DRY POWDER PRINTING AND SINTERING OF HOLLOW GLASS MICROSPHERES

Authors: Norman Wereley, Jungjin Park, John Howard, Matthew DeMay, Avi Edery

DOI: 10.33599/nasampe/s.23.0330

Abstract: The goal of this study is to develop lightweight core materials with tunable energy-absorbing properties. Hollow glass micro-spheres (HGMs) of different densities are layered using dry powder printing, an additive manufacturing process, and subsequently sintered to consolidate these microspheres into a cellular foam structure. Tunability of energy absorption is achieved in these foams by layering hollow microspheres with different densities and different layer thickness ratios. The mechanical response to quasi-static uniaxial compression of the bilayer foams fabricated using this method is also investigated. Bilayer samples exhibit a unique two-step stress-strain profile, with first and second plateau stresses, not achievable with single density or adhesively bonded structures. The strain where the second plateau occurs can be tuned by adjusting the relative thickness of the two layers enabling customization of the energy absorption profile of the structure. The tunability is found to be more significant if the difference in density between the two layers is large. For comparison, bilayer samples are fabricated using epoxy at the interface instead of the sintering process. Epoxy-bonded samples show a different mechanical response from the sintered samples with different stress-strain profiles. Sintering bilayer foams allows tuning of the stress-strain profile, which enables energy-absorbing properties that can be tuned to address the unique requirements of various impact conditions.

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Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000330

Pages: 15

Price: $30.00