The sound absorption capacity of one type of aluminum alloy foams-trade name Alporas-is studied experimentally. The foam in its as-received cast form contains closed porosities, and hence does not absorb sound well. To make the foam more transparent to air motion, techniques based on either rolling or hole drilling are used. Under rolling, the faces of some of the cells break to form small sharp-edged cracks as observed from a scanning electronic microscope. These cracks become passage ways for the in-and-out movement of air particles, resulting in sound absorption improvement. The best performance is nevertheless achieved via hole drilling where nearly all of the sound can be absorbed at selected frequencies. Combining rolling with hole drilling does not appear to lend additional benefits for sound absorption. Image analysis is carried out to characterize the changes in cell morphologies due to rolling/compression, and the drop in elastic modulus due to the formation of cracks is recorded. The effects of varying the relative foam density and panel thickness on sound absorption are measured, and optimal relative density and thickness of the panel are identified. Analytical models are used to explain the measured increase in sound absorption due to rolling and/or drilling. Sound absorbed by viscous flow across small cracks appears to dominate over that dissipated via ]other mechanisms.

The fluid-flow and heat-transfer features of cellular metal lattice structures made from copper by transient liquid phase (TLP) bonding and brazing of plane weave copper meshes (screens) were experimentally characterized under steady-state forced air convection. Due to the inherent structural anisotropy of this metal textile derived structure, the characterizations were performed for several configurations to identify the preferable orientation for maximizing thermal performance as a heat dissipation medium. Results show that the friction factor of bonded wire screens is not simply a function of porosity as stochastic materials such as open-celled metal foams and packed beds, but also a function of orientation (open area ratio). The overall heat transfer depends on porosity and surface area density, but only weakly on orientation. Comparisons with stochastic metal foams and other heat dissipation media such as packed beds, louvered fins and microtruss lattice cellular materials suggest that wire-screen meshes compete favorably with the best available heat dissipation media. The overall thermal efficiency index of the copper textiles-based media is approximately three times larger than that of stochastic copper foams, principally because of the lower pressure drop encountered during coolant propagation through the periodic wire-screen structure.

The effective thermal conductivity of steel alloy FeCrAlY (Fe-20wt.% Cr-5wt.% Al-2wt.% Y-20wt.%) foams with a range of pore sizes and porosities was measured between 300 and 800K, under both vacuum and atmospheric conditions. The results show that the effective thermal conductivity increases rapidly as temperature is increased, particularly in the higher temperature range (500-800K) where the transport of heat is dominated by thermal radiation. The effective conductivity at temperature 800K can be three times higher than that at room temperature (300K). Results obtained under vacuum conditions reveal that the effective conductivity increases with increasing pore size or decreasing porosity. The contribution of natural convection to heat conduction was found to be significant, with the effective thermal conductivity at ambient pressure twice the value of vacuum condition. The results also show that natural convection in metal foams is strongly dependent upon porosity.

The efficiency of micro-cell aluminium honeycombs in augmenting heat transfer in compact heat exchangers is evaluated using analytical models. For convective cooling, the overall heat transfer rate is found to be elevated by about two order of magnitudes when an open channel is designed with an aluminium honeycomb core. The performance is comparable to that achieved by using open-celled aluminium foams, but attributed to different mechanisms. At low Reynolds numbers (＜2000), the flow is essentially laminar in honeycombs, in contrast to the largely turbulent flow in metal foams; this deficiency in fluid dynamics is compensated for by the superior surface area density offered by honeycombs over foams. Another advantage of designing heat sinks with honeycombs is the relatively small pressure drop experienced and minimal noise generated by the laminar flow. The overall heat transfer rate of the heat sink is maximised when the cell morphology of the honeycomb is optimised[ However, the optimal cell morphology is not constant but dependent upon the geometry and heat transfer condition of the heat sink as well as the type of convective cooling medium used. For air cooling, the optimal relative density of the honeycomb is about 9.0. Other related e}ects, such as cell orientation and double cell wall thickness, are discussed.

The paper explores the use of open-celled metal foams as compact heat exchangers, exploiting convective cooling. An analytical model is developed for model foams with simple cubic unit cells consist-ing of heated slender cylinders, based on existing heat transfer data on convective crossflow through cylin-der banks. A foam-filled channel having constant wall temperatures is analyzed to obtain the temperature distribution inside the channel as a function of foam density, cell size and other pertinent heat transfer par-ameters. Two characteristic length scales of importance to the problem are discussed: the minimum channel length required for heating the fluid to its goal temperature and the thermal entry length beyond which the transfer of heat between fluid and channel wall assumes a constant coecient. The overall heat transfer coecient of the heat exchanging system is calculated, and the pressure drop experienced by the fluid flow obtained. These results are used to analyze and guide the design of optimum foam structures that would maximize heat transfer per unit pumping power. Two examples are given to demonstrate the applicability of the analytical model: heat sinks for high power electronic devices and multi-layered heat exchangers for aeronautical applications. The present model perhaps oversimpli