The tonal character of the low frequency internal noise in cars is often due to energy transmission through the tyre at the first few eigenfrequencies of the air cavity of the tyre. The first acoustic mode in the air cavity of a typical stationary car tyre is approximately 224 Hz. At this frequency the tyre is comparatively stiff resulting in a high transmission of energy from the road wheel contact to the car body itself. In order to investigate possible means of reducing this effect, the acoustic field inside a tyre is modelled. Theoretically it is found that the pressure inside a tyre and the energy transmission through the tyre to the wheel axle and the car body can be reduced by adding a sound absorbing material inside the tyre. This was confirmed by measurements on stationary as well as rotating tyres with and without added sound absorption. For a rotating tyre there is a split of the natural frequency depending on the rotational speed of the tyre. Measurements in a standard passenger car reveal that the noise level inside the car is rather high in a fairly wide frequency range around 224 Hz at normal velocities. This tonal noise can be reduced by adding sound absorption inside a tyre. Models for the prediction and the reduction of the tonal noise are presented. Measured and predicted results are compared and the agreement is found to be good. It is found that the tonal noise can be reduced by up to 9 dB. The effects of the air cavity resonances on the external noise have also been studied. It is estimated that external tyre noise can be reduced 1 dB by adding a sound absorbing material inside tyres. For a car travelling on a road a strong acoustic field is induced between the floor of the car and the road. The impact of this acoustic field can be reduced by mounting a sound absorbing material underneath the car. It is estimated that the A-weighted sound pressure level close to a running car could be reduced by 3 dB by adding this type sound absorption. It is found that aluminium foam could be a suitable sound absorbing material which could be mounted inside tyres and underneath cars. The acoustic and dynamic properties of various types of aluminium foams are discussed. In particular measurement techniques for determining sound absorption at grazing incidence are investigated. / QC 20100923

Metal foams have found increasing applications in a wide range of structural and functional products, due to their exceptional mechanical, thermal, acoustic and electrical properties and offer great potential for lightweight structures for energy absorption in packaging during impact at high velocities. Metal foam structures have densities only fractions of that of a solid structure and have high specific strength and higher stiffness than other contemporary packaging materials. Therefore, the metal foam in particular “Aluminium Foam” has an important application as packaging material for transportation of Reactor fuels and Radioactive samples. Nuclear materials are transported in packages which should meet stringent safety standards like impact resistance, thermal shock etc. Therefore, in the transportation of the above materials, aluminium foam can play a key role in providing a cushion for absorption of shock and impact. The aim of this work is to develop a process for fabrication of aluminum foam. Two methods are experimented to manufacture metal foams. The first method involves mixing of a foaming agent in a liquid aluminium pool and the subsequent cooling of the melt while hydrogen is released from the foaming agent. The second method of metal foaming process is based on a procedure consisting of a base metal and a foaming agent, which are milled for homogeneous mixing and then pre-compacted by cold isostatic pressing. This is followed by cold/warm extrusion. The extruded piece is then heated up to a certain foaming temperature. The heating process leads to partial metal melting as well as to the release of the hydrogen gas and consequently to the formation of metal foam in the semi-solid state. In this thesis, the technology for fabrication of Al foam having a density of around 0.2-0.3 g/cm3 has been made & discussed in detail. The effects of various fabrication parameters like compaction pressure, extrusion ratio and foaming temperature on the formation of the Al foam are discussed. The quality of fabricated Al foams is characterized in terms of density, microstructure, porosity content etc. The various mechanical properties like yield strength, tensile strength and impact energy of the Al foams are evaluated in order to understand their behavior under different conditions. The typical values of Young’s modulus, plateau stress, densification strain and energy absorbed for the foam tested are tabulated. The observations, which are made from the data, can be briefly quoted as under: a) As the length of the specimen increases, plateau stress increases which increases the energy absorption. b) The energy absorption for Al-20% Mg alloy has been found to be minimum. The foam exhibited brittle behaviour and crumbled under load application. c) Young’s modulus varies in the range of 0.057 – 0.13 GPa for the foam. d) As density increases, Young’s modulus also increases and correspondingly the energy absorption value increases for Al-foam. It is found that the variation in the plateau stress with density is marginal. But the strain value was found to be dependent on the alloy composition and the density. The strain obtained for all cases was found to be very near to 75-90%. Al-20%Mg alloy showed an inferior behaviour compared to pure Al. It showed a lesser plateau stress and crumbled while testing. This shows that this alloy is highly brittle in nature. Also, the Al-Mg foam obtained did not exhibited good luster.