This article presents the results of a study of the microstructure and strength of open-cell 6101 aluminum alloy fans with three different levels of pore size (measured in pores per inch (PPI)). The macrostructures and microstructures of open-cell foam struts are characterized using a combination of optical and scanning electron microscopy (SEM). The compositions of the individual phases are also determined via energy-dispersive spectroscopy (EDS). The variations in strut microhardness are then measured using Vickers microindentation techniques. Following the measurement of the mechanical properties of foams, a modified model is used to estimate the relative density from measured strut dimensions. The mechanisms of compressive deformation are then elucidated before presenting a discussion on unit-cell modeling, strut plastic deformation, and the relationships between strut micro-structure and microhardness.
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