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<p>This study aims to evaluate the bending stiffness and energy absorption capacity of a novel kind of metallurgically bonded aluminum foam sandwich (AFS) beams fabricated based on the melt route, and to explore the effects of core relative density, faceplate thickness (1–3&#xa0;mm), and test temperature (25–400&#xa0;°C) on their performance and failure modes. By combining experimental results with theoretical models (Timoshenko beam theory and the modified Gibson–Ashby model), it was found that the experimental stiffness values are in high agreement with the theoretical predicted values under different core densities and panel thicknesses, and the deviations are mostly within 20%. The experiment results show that increasing core density significantly enhances specific stiffness and energy absorption, but specific energy absorption decreases due to increased mass when relative density exceeds ~ 0.2. Elevated temperatures induce significant softening, reducing load-bearing capacity and transitioning core failure modes from brittle shear (cleavage-dominated fracture at ambient conditions) to ductile yielding (dimple-dominated fracture above 400&#xa0;°C). No macroscale extensive delamination occurred at the metallurgically bonded interface during deformation, ensuring structural integrity. This research provides theoretical support for the design of lightweight structures, with experimental insights into their performance at elevated temperatures, and emphasizes the importance of interfacial durability under thermal–mechanical coupling.</p> Graphical abstract <p></p>

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Exploring three-point bending response of novel aluminum foam sandwich beams fabricated by melt route

  • 期刊论文

  • 发表日期：

    2025年6月11日

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  • Li Wang,
  • Hongjie Luo,
  • Shibo Cui,
  • Linli Wu,
  • Jianrong Xu

摘要

This study aims to evaluate the bending stiffness and energy absorption capacity of a novel kind of metallurgically bonded aluminum foam sandwich (AFS) beams fabricated based on the melt route, and to explore the effects of core relative density, faceplate thickness (1–3 mm), and test temperature (25–400 °C) on their performance and failure modes. By combining experimental results with theoretical models (Timoshenko beam theory and the modified Gibson–Ashby model), it was found that the experimental stiffness values are in high agreement with the theoretical predicted values under different core densities and panel thicknesses, and the deviations are mostly within 20%. The experiment results show that increasing core density significantly enhances specific stiffness and energy absorption, but specific energy absorption decreases due to increased mass when relative density exceeds ~ 0.2. Elevated temperatures induce significant softening, reducing load-bearing capacity and transitioning core failure modes from brittle shear (cleavage-dominated fracture at ambient conditions) to ductile yielding (dimple-dominated fracture above 400 °C). No macroscale extensive delamination occurred at the metallurgically bonded interface during deformation, ensuring structural integrity. This research provides theoretical support for the design of lightweight structures, with experimental insights into their performance at elevated temperatures, and emphasizes the importance of interfacial durability under thermal–mechanical coupling.

Graphical abstract