Process–microstructure–property relationships in AA3003 expanded metal periodic cellular truss cores

Despite their significant potential as ultra-lightweight composite materials, comparatively little attention has been given to the microstructure of deformation formed periodic cellular metals (PCMs). Because shape plays such a determining role in their performance, it is the spatial distribution of microstructure which controls both the useful range of cellular architectures and their resultant mechanical properties. The present study examines the effects of non-uniform recrystallization in expanded AA3003 sheet precursors on the PCM composite formability and mechanical performance. Because fabrication induced work-hardening and crack formation is localized to the hinge region, the pre-annealing temperature prior to fabrication provides a trade-off between the resultant compressive modulus and inelastic buckling strength of the PCM.