International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 7, Issue 6, Dec 2017, 1-10
© TJPRC Pvt. Ltd.

STUDY OF MECHANICAL PROPERTIES OF OPEN CELL AL6061 ALLOY FOAM

RAJA YATEESH YADAV1 &E S PRAKASH2

1
Shri Madhwa Vadiraja Institute of Technology & Management, Bantakal, Udupi, India
2
University B D T College of Engineering, Davangere, India
ABSTRACT

The mechanical behavior of 20 ppi open cells Al6061 alloy foam is studied under uniaxial tensile,
compression and bending loads. In addition to the common stress–strain measurements, peak load, ultimate stress,
displacement at peak load, break load, displacement at break load, breaking stress and Percentage reduction in the
cross-sectional area for two specimens were determined. The results show that even though aluminium foams were
having good thermal and damping properties, they are having poor mechanical properties hence they are not suitable
load bearing structures.

KEYWORDS: uniaxial tensile, break load & load bearing structures

Received: Aug 22, 2017; Accepted: Sep 20, 2017; Published: Oct 14, 2017; Paper Id.: IJMPERDDEC20171

Original Article
INTRODUCTION

The recent development of a number of cost-effective processes for making metallic foams has increased
their potential for application in sandwich panels for lightweight structural components, in energy absorption
systems for protection from impacts, in heat sinks for electronic devices and acoustic insulation. [1] In the last few
year structural efficiency, cost requirements and improvements in manufacturing processes have created renewed
interest in metallic foams. For a successful design with this new class of materials, their mechanical properties
have to be known. Most work has been performed on their compressive properties and energy-absorbing
behaviour; see for example [2–5]. But for the design of load bearing structural elements such as sandwich panels,
other mechanical properties (tension behaviour, fracture toughness, etc.) are needed as well. The aim of this
investigation was to provide information about the tensile performance and deformation behaviour of aluminium
foams.

In compression, aluminium foams show different regimes of deformation. The most important one is the
plateau regime, where the stress remains nearly constant with increasing deformation. This plateau stress is caused
by the initiation and propagation of deformation bands through the foam structure [6]. In these bands the
deformation predominantly takes place by plastic buckling of the cell edges and cell walls. The plastic Poisson’s
ratio in compression at larger strains is about zero. In tension, however, it is expected that buckling plays a minor
role in the deformation mechanisms. Therefore a different deformation behaviour is anticipated.

Only a few investigations (e.g., [7, 8]) exist that are concerned with this topic. In this paper, the
mechanical behaviour of 20 ppi open cells Al6061 alloy foam is studied under uniaxial tensile loading.

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2 Raja Yateesh Yadav & E S Prakash

MATERIALS AND METHODS

Physical and Chemical properties of Al6061 alloy

The selection of the material for foam fabrication is generally based on the end application. In the present
research, Aluminum 6061 alloy (Al 6061 alloy) is chosen for the foam fabrication, as it exhibits good structural, chemical,
thermal, electrical, heat transfer properties and weldability. Table 1.1 shows the composition of Al 6061 alloy.

Table 1: Chemical Composition of Al 6061 Alloy by Weight Percentage

Mg (Magnesium) 0.920 %
Si (Silicon) 0.750 %
Fe (Ferrous) 0.280 %
Cu (Copper) 0.220 %
Ti (Titanium) 0.100 %
Cr (Chromium) 0.070 %
Zn (Zinc) 0.060 %
Mn (Manganese) 0.040 %
Be (Beryllium) 0.003 %
V (Vanadium) 0.010 %
Al (Aluminum) Balance

Table 2: Physical, Thermal, Electrical Properties of Al 6061 Alloy

Density, kg/m3 2700
Melting point, °C 580
Modulus of elasticity, GPa 70-80
Co-Efficient of Thermal Expansion (20-100°C) m/m °C 23.5x10-6
Thermal Conductivity, W/m°C 173
Electrical Resistivity Ω cm 3.7 – 4.0 x10-6
Poison’s ratio 0.33

Closed cell metal foams provide good mechanical properties but do not allow access to their internal surface.
Therefore, they are mostly used in structural and load bearing applications. Open cell metal foams are more suitable heat
transfer applications, as they provide more surface area for the heat transfer. The present research is more concentrated on
the study of heat transfer applications of metal foams, an open cell metal foam is fabricated using Al6061 alloy.

EXPERIMENTAL PROCEDURE
Specimen Preparation

The specimens were prepared by machining from commercially available 20 ppi Al6061 foam. Totally five
specimens of different dimensions with rectangular sections are prepared. Two of them were used for tensile test, two are
used for compression test and the rest one being used for bending test.

Tensile Test

Tensile test is a fundamental materials science test in which a sample is subjected to a controlled tension until
failure. The results from the test are commonly used to select a material for an application, for quality control, and to
predict how a material will react under loading condition. Properties that are directly measured through tensile test
are ultimate tensile strength, maximum elongation and reduction in area. Uniaxial tensile testing is the most commonly
used for obtaining the mechanical characteristics of isotropic materials. The testing process involves placing the test
specimen on the Universal Testing Machine (UTM) and applying the uniaxial tensile force until the specimen breaks.

Impact Factor (JCC): 6.8765 NAAS Rating: 3.11

Study of Mechanical Properties of Open Cell AL6061 Alloy Foam 3

An open cell Al foam specimen of 20 ppi made from Al6061 alloy is cut into a required
require dimension using a cutter
wheel and the edges are finished for mechanical testing. Two specimens are tested for the study of tensile properties.

Figure 1: Tensile Test Specimen-1

Figure 2: Tensile Test Specimen-2

Figure 3: Tensile Test Specimen-1 under Loading in the UTM Set Up

Fig
Figure 4: Tensile Test Specimen-1 after the Test

Figure 5: Tensile Test Specimen-2 after the Test

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4 Raja Yateesh Yadav & E S Prakash

Compression Test

Compression test is to determine the behavior or response of a material while it experiences a compressive load.
In general a compression test for a material involves at least two opposing forces directed towards each other applied to the
opposite face of the test sample so that the sample is compressed. Compression tests are run in much the same manner as
the tension test on the specimen having an initial rectangular cross-sectional area. Testing is carried out on Universal
Testing Machine. For each load interval, respective change in length is measured and the same is recorded until breaking
takes place.

Figure 6: Compression Test Specimen-1

Figure 7: Compression Test Specimen-2

Figure 8: Compression Test Specimen under Loading in UTM Set Up

Impact Factor (JCC): 6.8765 NAAS Rating: 3.11

Study of Mechanical Properties of Open Cell AL6061 Alloy Foam 5

Figure 9: Compression Test Specimens after the Test

Bending Test

The bend test is essentially measuring the ductility of a specimen. Ductility defines how easily a specimen can
bend without breaking. The higher the ductility of a metal, the more it can bend without breaking or becoming deformed
from its original shape.

Figure 10: Bending Test Specimen-1

Figure 11: Bending Test Specimen under Loading in UTM Set Up

Figure 12: Bending Test Specimens after the Test

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RESULTS AND DISCUSSIONS

Tensile test

Figure-13 and Figure-14 shows the Load vs Displacement curve for tensile test specimen-1 and specimen-2
respectively. The tensile test results of the specimen-1 are as follows.

Peak load = 1726 N

Ultimate stress = (Peak load/Initial cross-sectional area) = 3.95 N/mm2

Displacement at peak load = 1.655 mm

Break load = 88.26 N

Displacement at break load = 2.97 mm

Breaking stress = (Break load/Initial cross-sectional area) = 0.2023 N/mm2

Final cross-sectional area = 411.81 mm2

Percentage reduction in the cross-sectional area = 5.60%

The tensile test results of the specimen-2 are as follows.

Peak load = 3050 N

Ultimate stress = (Peak load/Initial cross-sectional area) = 3.46 N/mm2

Displacement at peak load = 2.138 mm

Break load = 98.07 N

Displacement at break load = 4.23 mm

Breaking stress = (Break load/Initial cross-sectional area) = 0.2401 N/mm2

Final cross-sectional area = 376.53 mm2

Percentage reduction in the cross-sectional area = 7.80%

Figure 13: Load vs. Displacement Curve for Tensile Test Specimen-1

Impact Factor (JCC): 6.8765 NAAS Rating: 3.11

Study of Mechanical Properties of Open Cell AL6061 Alloy Foam 7

Figure 14: Load vs. Displacement Curve for Tensile Test Specimen-2

From the results of tensile test, the average maximum tensile load that the Al6061 foam specimen can take is
found to be 2388 N and the average ultimate stress is found to be 3.70 N/mm2.These values are less compared to the
conventional materials used for load bearing applications.

Compression Test

Figure-15 and Figure-16 shows the Load vs Displacement curve for compression test specimen-1 and specimen-2
respectively. Compression test results of the specimen-1 are as follows.

Peak load = 15691.2 N

Compressive stress = (Peak load/Initial cross-sectional area) = 39.36 N/mm2

Displacement at peak load = 28.309 mm

Break load = 15691.2 N

Displacement at break load = 28.309 mm

Compression test results of the specimen-2 are as follows.

Peak load = 13788.60 N

Compressive stress = (Peak load/Initial cross-sectional area) = 28.099 N/mm2

Displacement at peak load = 11.728 mm

Break load = 13788.60 N

Displacement at break load = 11.728 mm

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8 Raja Yateesh Yadav & E S Prakash

Figure 15: Load vs. Displacement Curve for Compression Test Specimen-1
Specimen

Figure 16: Load vs. Displacement Curve for Compression Test Specimen-2
Specimen

From the results of compression test, the average peak load that the Al6061 foam specimen can take is found to be
14739.9 N and the average compression strength is found to be 33.72 N/mm2.These values are less compared to the
conventional materials used forr load bearing applications.

Bending Test

Figure-17 shows the Load vs Displacement curve for bending test specimen.
specimen. Bending test results are as follows.

Peak load: 0.340 kN

Elongation at peak: 4.95 mm

Bending strength: 0.877 N/mm2

Figure 17: Load vs. Displacement Curve for Bending Test Specimen

From the results of bending test, the peak load that the Al6061 foam specimen can take is found to be 0.34 kN and
the bending strength is found to be 0.877 N/mm2.These values are less compared to the conventional materials used for

Impact Factor (JCC): 6.8765 NAAS Rating: 3.11

Study of Mechanical Properties of Open Cell AL6061 Alloy Foam 9

load bearing applications.

CONCLUSIONS

A 20 ppi Al6061 alloy foam specimen is tested for uniaxial tensile, compression and bending loads. Based on the
results, the following conclusions can be made.

• The ultimate tensile strength of Al6061 alloy foam specimen is found to be 3.70 MPa. This value is very less
compared to ultimate tensile strength of mild steel, a conventional material whose ultimate tensile strength will be
around 841 MPa. Hence Al6061 alloy foam cannot used for structures required to bear tensile loads.

• The ultimate compression strength of Al6061 alloy foam specimen is found to be 33.72 MPa. Again, this value is
very less compared to the ultimate compression strength of mild steel, a conventional material whose ultimate
compression strength will be around 250 MPa. Hence Al6061 alloy foam cannot used for structures required to
bear compression loads too. Also, the specimen tested is of open cell type, the specimen is almost squeezed at the
end of the test.

• Also, porous materials cannot be used applications, where the structures are subjected to bending loads, as foam is
a very brittle material.

REFERENCES

1. E. Andrews, W. Sanders, L.J. Gibson “Compressive and tensile behaviour of aluminum foams” Materials Science and
Engineering A270 (1999) 113–124

2. Bart-Smith, H., Bastawros, A. -F., Mumm, D. R., Evans, A. G., Sypeck, D. J. and Wadley, H. N. G., Acta. mater., 1998, 46(10),
3583.

3. Fusheng, H., Zhengang, Z. and Junchang, G., Metall.Mater. Trans., 1998, 29A, 2497.

4. Gradinger, R. and Rammerstorfer, F. G., Acta. mater.,1999, 47(1), 143.

5. Andrews, E., Sanders, W. and Gibson, L. J., Mater. Sci. Eng., 1999, A270, 113.

6. Bastawros, A. -F., Bart-Smith, H. and Evans, A. G., J. Mech. Phys. Solids, 2000, 48, 301.

7. Sugimura, Y., Meyer, J., He, M. Y., Bart-Smith, H., Grenstedt, J. and Evans, A. G., Acta Mater, 1997, 45(12), 5245.

8. Olurin, O. B., Fleck, N. A. and Ashby, M. F., Mater. Sci. Eng., 2000, A291, 136.

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