Application of Aluminum Alloy Syntactic Foams with

Silicon Carbide Microspheres in Commercial Track Spikes

Arch Latham
Packer Collegiate Institute
February 24, 2017

Dr. Nikhil Gupta, Steven Zeltmann

NYU Tandon School of Engineering
Abstract:

The goal of this project is to investigate the application of aluminum alloy syntactic foams

with silicon carbide microspheres in commercial track spikes. Syntactic foams with aluminum or

aluminum alloy matrixes show a lot of potential in the manufacturing world and I believe those

with silicon carbide microspheres would be useful in recreational and professional track and

field settings. Several spikes would be produced using pressure infiltration synthesis of foams at

different hollow particle volume fractions. High strain rate compression testing and practical field

testing would be used to asses the compressive ability and overall function of these spikes.

Ideally at the end of this project I can find a volume fraction for a syntactic foam that would work

well in track spikes by reducing weight, handling compression of foot strike, and ultimately

serving the runner.

Introduction:

Syntactic foams are a form of composite defined by hollow particles dispersed

throughout a matrix at a defined volume fraction.[1] Syntactic foams offer a lot of promise in the

world of material engineering as the hollow form of the particles reduce the density of the whole

material while maintaining significant compressive strength.[1] Foams with an aluminum or

aluminum alloy matrix and silicon carbide particles (Al-SiC) are highly studied for their potential

use in parts manufacturing throughout aerospace, marine, military, and commercial areas.[2] The

strength of the silicon carbide ceramic compliments the light weight of the aluminum or

aluminum alloy in the context of the attributes of syntactic foams.[2]

Pressure infiltration is a means of synthesizing syntactic foams in which a bed or preform

mold of hollow particles is prepared and molten metal is injected into the mold using high

pressure against a vacuum.[1] This method of synthesis presents the advantage of production of
foams that have a high volume fraction with even spread of hollow particles.[1] The process can

be problematic in some scenarios though in terms of cost and lack of temperature control

leading to lesser structural strength within the foam.[1]

A high strain rate compression test is a test that can be conducted using a

Split-Hopkinson pressure bar to collect data on the the strain rate, strain, and stress a material

experiences.[3] The test is performed by placing the material between two bars and rapidly

striking one with a pressure gun.[3] Stress is a measure of force per area, strain is a measure of

deformation by distance, and strain rate is the rate at which this deformation takes place.[4] After

the tests are performed at a static pressure these values are calculated and graphed against

each other so that insight can be offered into the compressive capabilities of the material.[4]

Track spikes are a common product in recreational and professional track and field

settings that use metal spikes to grip and push the runner off the track. Typically the replaceable

metal spikes on the bottom of the shoes used to grip the track are made of cheap metal but a

market exists for innovative spikes that crucially reduce weight and creatively use compression

of the track to the runners advantage. Even slight weight reduction of spikes can improve the

race time of a runner and is extremely desired in competitive track and field events.

Proposal:

I believe that Al-SiC syntactic foams produced through pressure infiltration at high

volume fractions of hollow particles would be useful in application of commercial track spikes.

The light weight of the syntactic foams would be extremely desirable to athletes looking to

improve their times while the compressive abilities would offer adequate and possibly beneficial

strength against the track. Composites that have significant aerospace and military application

have often also found use in commercial athletic markets. I would like to perform high strain rate
compression tests against several spike shaped Al-SiC composites with varying hollow particle

volume fractions. The goal of the project would be to find a premium volume fraction for the

syntactic foam that can offer the lowest possible weight while sustaining adequate compressive

abilities in a competitive track setting. A timeline of the project would include initial synthesis of

the different spikes by a third party followed by high strain rate compressive testing of each

spike. Next analysis of data will take place and after findings are taken into consideration it is

optional a second round of high strain rate testing could take place with a more refined range of

volume fractions followed by possible practical testing on a track.

Methodology:

Materials:

Initially six different kinds of spikes would be produced by pressure infiltration at volume

fractions of 30%, 40%, 50%, 60%, 70%, and 80%. The matrix of all spikes would use an A356

aluminum alloy and the particles of all spikes would be made from SiC ceramic and have a

diameter of 1 mm and wall thickness of 70 m. If a second round of testing takes place five

different kinds of spikes will be produced with volume fractions within a 20% range varying by

5% (Ex: 60%, 65%, 70%, 75%, 80%)

 Fig 1: CAD model of spike, (40 units = 1 in)

High Strain Rate Testing and Analysis:

Tests on each spike would be conducted using a Split-Hopkinson pressure bar. Because

test is not conducted with a chosen variable of force and rather data is produced based on

calculations of bar displacement, several tests would be conducted at a static pressure against

each different spike variant until adequate data is collected. Strain rate, stress, and strain will be

calculated and compared graphically so the stress-strain curves can be assessed.

Practical Testing:

After data analysis from high strain rate testing is conducted and a range of most effect

volume fractions for the second generation of spikes is found I would personally conduct

practical tests across several days by running ten 200m heats with each spike and recording

time splits. Using time data and personal experience I should be able to determine the syntactic

foam best suited for use in track spikes.

Bibliography:

[1] Gupta, N., Pinisetty, D., & Shunmugasamy, V. C. (2013). Compressive Properties.
Reinforced Polymer Matrix Syntactic Foams SpringerBriefs in Materials, 43-52.
doi:10.1007/978-3-319-01243-8_6

[2] Luong, D. D., Strbik, O. M., Hammond, V. H., Gupta, N., & Cho, K. (2013). Development of
high performance lightweight aluminum alloy/SiC hollow sphere syntactic foams
and compressive characterization at quasi-static and high strain rates. Journal of
Alloys and Compounds, 550, 412-422. doi:10.1016/j.jallcom.2012.10.171

[3] Z.Y. Dou, L.T. Jiang, G.H. Wu, Q. Zhang, Z.Y. Xiu, G.Q. Chen, High strain rate compression
of cenosphere- pure aluminum syntactic foams, Scripta Materialia, 57 (2007)
945-948.

[4] Balch, D., & Dunand, D. (2006). Load partitioning in aluminum syntactic foams containing
ceramic microspheres. Acta Materialia, 54(6), 1501-1511.
doi:10.1016/j.actamat.2005.11.017