Compressive behavior of a Zn22Al2Cu cellular alloy with different densities, microstructures and cell shapes

Zn22Al2Cu cellular alloy was prepared with six different densities, two microstructures and two cell shapes to determine the effect of these factors on its compressive behavior. NaCl granules with sharp edges, as purchased and with smooth edges obtained by roughly polishing the purchased granules were used as spacers. The elaboration process of the alloy foam consisted of melting the alloy, immersing the granules in the liquid alloy, air-cooling and then dissolving the salt in boiling water. The matrix obtained with the materials had an as-cast microstructure, and a fine microstructure, which was achieved with a heat treatment applied prior to dissolving the NaCl granules. Samples were tested in compression at a 10^-3 s^-1 strain rate. The smooth shape of the cells caused that the as-cast microstructure in the matrix produces an elastic behavior, which is described by the equation derived by Ashby for the relative elastic modulus and the relative density of sponges. The same type of cell shape embedded in the fine microstructure produces an elastic behavior in compression that depends on the density, which is typical of very low-density foams, although much lower than those achieved in this study. Compressive behavior is chaotic when cells have sharp shape, regardless microstructure type. The alloy studied with 4 mm mean size cells has a compression behavior like a sponge or low-density foam, when its cell walls have smooth contours, and as-cast or fine microstructure, respectively.