Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting

Abstract

Nowadays, fuel consumption and carbon dioxide emissions are two of the main focal points in vehicle design, promoting the reduction in the weight of vehicles by using lighter materials. The aim of the work is to evaluate the influence of different aluminium foams and injection parameters in order to obtain compound castings with a compromise between the obtained properties and weight by high-pressure die cast (HPDC) using aluminium foams as cores into a magnesium cast part. To evaluate the influence of the different aluminium foams and injection parameters on the final casting products quality, the type and density of the aluminium foam, metal temperature, plunger speed, and multiplication pressure have been varied within a range of suitable values. The obtained compound HPDC castings have been studied by performing visual and RX inspections, obtaining sound composite castings with aluminium foam cores. The presence of an external continuous layer on the foam surface and the correct placement of the foam to support injection conditions permit obtaining good quality parts. A HPDC processed magnesium-aluminium foam composite has been developed for a bicycle application obtaining a suitable combination of mechanical properties and, especially, a reduced weight in the demonstration part.

Repairing Hybrid Mg–Al–Mg Components Using Sustainable Cooling Systems

“…Most studies focused on machining processes [105][106][107][108][109][110][111][112][113] and tried to find the optimal combination of machining conditions and lubrication/cooling systems by means of experimental tests, taking the surface roughness required in a particular industry sector or application as a response variable. Others dealt with friction and wear between contact materials [114,115], the effects of pre-treatments on the adhesion of hybrid materials [116], innovative techniques for forming these types of components [117,118], or identification of some of the most prominent issues.…”

Experimental Study for Improving the Repair of Magnesium–Aluminium Hybrid Parts by Turning Processes

“…The geometry of the specimens raised in the present study is a natural evolution of the geometries and materials previously studied separately that have just been mentioned. In addition, the selected materials, both independently and jointly, have been used by other researchers in different investigations with good results in the field of study [61][62][63][64][65][66][67][68][69][70][71]. The geometry of the specimen [45] (Figure 2) and the composition of these alloys (Table 3) …”

Fabrication of 17‐4PH Stainless Steel Foam by a Pressureless Powder Space Holder Technique

“…[ 22,23 ] Although these compaction techniques are maturing, the relatively high tooling cost of the compaction process, as well as size and shape limitations have reduced the feasibility of using powder metallurgy processes to produce metallic foams rather than the less‐expensive, molten‐metal foaming process. [ 24,25 ]…”