On the bending behaviour and the failure mechanisms of grid-reinforced aluminium foam cylinders by using an experimental/numerical approach

Metal foams are attracting interest in both aerospace and automotive industries due to their intriguing properties such as high stiffness coupled with low specific weight, good absorbing energy capabilities and flame resistance. To date, many researchers are trying to develop innovative solutions for the improvement of the mechanical properties of metal foams keeping the light-weight condition, with the scope to extend their potential application field. In this scenario, an advanced solution was here proposed; in particular, an innovative manufacturing process was presented for the production of steel grid–reinforced closed-cell aluminium foam cylinders in one single step by using the powder compact melting technique. The bending properties of plain, as well as reinforced, foam systems were experimentally tested and extensively discussed. An original finite element model was developed and validated for the analysis of the bending behaviour and the synergistic action of each component constituting the hybrid system, with a special focus on the failure mechanisms occurring under specified load conditions. The outcomes showed an increase of the mechanical properties of the reinforced systems due to the action of the light-weight mesh grid reinforcement that delays the failure of the structure. The solution proposed shows promises of being a useful method to expand the industrial applications of metal foams.