Aluminum Melt Foam Processing for Light-Weight Structures

Abstract

Aluminum foam was prepared by two routes, namely, gas injection technique and by the decomposition of TiH₂ blowing agent. The foam structure can be largely controlled by the amount of degassing agent and duration of foaming. The heterogeneity in cell structure could be explained on the basis of foam stability, drainage in the cell walls, and heat transfer during quenching. The variation in cell size and drainage is negligible when the holding time is around 120 s at 750°C. The constant strain rate compression tests indicate that the Young's modulus, plateau stress, and energy absorption capacity increases with relative density of the foam, while the densification strain reduces with increase in relative density.

Keywords:

• Aluminum alloy
• Automotive applications
• Blowing agent
• Cell structure
• Closed-cell
• Decomposition
• Energy absorption
• Foam processing
• Gas/air injection
• Light-weight structure
• Low density
• Mechanical properties
• Metallic foams
• Plateau stress
• Relative density