The study evaluates mechanical properties of APM particulate aluminum foams built up from adhesively bonded Al foam spheres. Foams of matrix alloy AlSi10 are compared, with PM AlSi7 foams used as reference. The influence of density is studied both for quasi‐static and dynamic compressive loading in a range from ∼0.35 to 0.71 g cm−3. The effect of varying the bonding agent is evaluated for a single density and both strain rate levels by replacing the standard, high‐strength epoxy‐based adhesive with a polyamide of greatly increased ductility. The result is a clear shift of fracture events to higher strain levels, as well as the introduction of a strain‐rate dependency of strength.
The advantages advanced pore morphology (APM) and a reduction in production complexity are discussed. These two aspects are key to low-cost PM manufacturing of aluminum foam parts. APM approach is based on the separation of the two main steps of the powder metallurgical process for production of metal foam parts, namely foam expansion and part shaping. APM metal foam parts consist of small-volume foam elements joined to each other in a separate process step. It is pointed that with a reduced part price, existing markets could be served with low-cost but high-quality metal foam parts
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