Metal Foam Shell Structure for Acoustic Lightweight Components
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Solution Overview
Problem
Existing methods for manufacturing components often compromise on weight, cost, or time due to the monolithic nature of raw materials, making it challenging to produce lightweight components that meet performance criteria while being cost-effective.
Innovation Solution
A method involving a metallic foam core formed into a desired configuration using hot or cold forming and machining processes, followed by the application of an external metallic shell via spray processes, with optional resonant chambers and openings for acoustic attenuation, to create a lightweight, rigid structure with tailored structural and acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If subtractive manufacturing or machining oversized blocks is used to meet performance criteria, then the component meets the required performance, but the component weight increases and material waste increases
Solution Approach 1:
The component is divided into two distinct parts: a metallic foam core providing the required structural performance and an external metallic shell providing the final surface finish and dimensional accuracy. This segmentation allows each part to be optimized independently - the foam core can be lightweight while the shell provides the necessary performance characteristics.
Solution Approach 2:
The invention uses a composite structure combining metallic foam and metallic shell materials. This composite approach allows the component to achieve the desired performance criteria through the synergistic combination of materials rather than relying on a single monolithic material, reducing overall weight while meeting performance requirements.
2Reliability
If subtractive manufacturing or machining oversized blocks is used to meet performance criteria, then the component meets the required performance, but the manufacturing time and cost increase
Solution Approach 1:
The metallic foam core is pre-formed into a configuration that is slightly smaller than the final dimensions, and the external metallic shell is applied beforehand. This preliminary action reduces the amount of subsequent machining required, significantly decreasing manufacturing time while still achieving the required performance criteria.
Solution Approach 2:
By segmenting the manufacturing process into separate steps for forming the foam core and applying the shell, the invention allows for more efficient production methods compared to machining a single monolithic block, thereby improving productivity and reducing manufacturing time.
3Strength
If a monolithic material structure is used, then the component achieves required strength, but the component weight and material usage increase
Solution Approach 1:
The composite structure of metallic foam core and metallic shell provides the required strength through the combined properties of the two materials. The foam core offers structural integrity while the shell provides additional strength and surface durability, achieving the required strength with reduced weight compared to a monolithic structure.
Solution Approach 2:
The external metallic shell is applied to provide localized quality enhancement at the component's exterior surfaces, providing the necessary strength and surface properties where needed, while the interior foam core provides lightweight structural support. This local differentiation of material properties optimizes the strength-to-weight ratio.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in low-cost, lightweight components with improved structural rigidity and acoustic attenuation capabilities, reducing material waste and manufacturing time, and enabling complex shapes that were previously difficult to produce.
Implementation Method 1
the sheet of metallic foam is formed to the desired configuration by a hot or cold forming process wherein the sheet of metallic foam is placed in a die
Implementation Method 2
the sheet of metallic foam is formed to the desired configuration by a hot or cold forming process
Implementation Method 3
the external metallic shell is applied via a spray application process, wherein the spray application process is selected from the group comprising: flame spray application process; plasma spray application process; and cold-spray application process
Implementation Method 4
the external metallic shell is applied via a spray application process, wherein the spray application process is selected from the group comprising: flame spray application process; plasma spray application process; and cold-spray application process
Implementation Method 5
attenuating the component to a frequency by forming a plurality of openings in the external metallic shell
Implementation Method 6
forming a plurality of resonant chambers in the metallic foam core prior to the application of the external metallic shell, wherein at least some of the plurality of openings are in fluid communication with a respective one of the plurality of resonant chambers
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A method of making a light weight component (28) is provided. The method including the steps of: forming a metallic foam core (11) into a desired configuration; applying an external metallic shell (20) to an exterior surface of the metallic foam core after it has been formed into the desired configuration; and attenuating the component to a desired frequency by forming a plurality of openings (34) in the external metallic shell.