Flexural Response of an Aluminum Foam Core/Stainless Steel Facesheet Sandwich Composite

In this work we have prepared open-cell Al foam core sandwich composites (AFS) with stainless steel (SS) facesheets. In the existing literature, the foam core and facesheets are joined using an adhesive, which limits their application. In the present study, the open-cell Al foam is attached to the SS facesheets using an Al-Zn filler to create a solder joint. The prepared sandwich composites were evaluated for joint integrity based on Vickers microhardness, nanoindentation and microstructure observation using optical and scanning electron microscopy. The microstructural observation showed a defect-free joint between the facesheet and foam core struts. Three-point bend tests on the sandwich showed core shear as the major failure mechanism, which corresponded well with the failure mode map established using Gibson’s model, based on the AFS dimensions and constituent properties. The methodology utilized in creating AFS and the results from present work can greatly benefit the aerospace, automotive and oil and gas sectors.