Roll formability of aluminium foam sandwich panels

  • Matthias Weiss
  • Buddhika Abeyrathna
  • Michael Pereira


An aluminium foam sandwich (AFS) material was formed by V-die bending and roll forming. The V-bent sections showed material failure by shear fracture of the aluminium foam core and by delamination at the core-cover sheet interface. This led to a high-gull wing defect and a limited section depth that could be formed. In contrast, the roll forming process allowed the manufacture of long sections with acceptable profile depth. Only minor gull wing was observed, and this was related to a low-shear deformation of the aluminium foam core and an intact adhesion at the core-cover sheet interface. The higher material formability observed in roll forming compared to that in V-die bending was attributed to a more evenly distributed contact pressure and more homogeneous forming, due to the incremental nature of the process, combined with a continuous contact of the metal sheet with the top and bottom rolls. Some forming problems were also observed in the roll-formed AFS components, but overall, the results of this study suggest that roll forming represents a good alternative to bending or stamping for the forming of longitudinal components of simple cross section shape that are of interest to the transport, solar or housing industries.


Aluminium foam Sandwich Bending Roll forming Gull wing defect 


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The authors would like to acknowledge the assistance of Emeritus Professor J.L. Duncan in writing this paper. The authors further would like to thank Josu Azkune, John Hore and Marius Kaiser for their assistance in the experimental work of this paper.

Funding information

The authors further appreciate the financial support of the Australian Research Council (ARC Linkage grant—LP120100111), the Wuhan Iron and Steel (Group) Corp (WISCO), DataM Sheet Metal Solutions and Australian Rollforming Manufacturers and the Global Training 2012 Program of the Basque Government.


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Matthias Weiss
    • 1
  • Buddhika Abeyrathna
    • 1
  • Michael Pereira
    • 2
  1. 1.Institute for Frontier MaterialsDeakin UniversityGeelongAustralia
  2. 2.School of EngineeringDeakin UniversityGeelongAustralia

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