Aluminium foam sandwich structures for space applications

Schwingel, Dirk; Seeliger, Hans-Wolfgang; Vecchionacci, Claude; Alwes, D.; Dittrich, Jürgen

doi:10.1016/j.actaastro.2007.01.022

Cited by 85 publications

(33 citation statements)

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“…[65] The starting powders are supplied by powder manufacturers and are processed at 'alm'. Processing includes drying of the met- [34], [37], [38], [41], [43] 2E: [39] MA2: [40] MP: [42] [45] PA: [44] (c) AlSi7 (PM, TiH 2 ) Al 3XXX M: [46] P: [47], [52], [53] 2: [48], [49], [50], [51] (c) AlSi6Cux (PM, TiH 2 ) Al 6XXX S: [54] P: [55], [53] A: [56] (c) AlSi12 (PM, TiH 2 ) steel MP: [57] (b) AlSi12 (PM, TiH 2 ) Al P: [58] (d) AlSi9Cu3 (LM, MgH 2 ) =foam MSP: [36] (c) 5XXX (ARB, TiH 2 ) =foam M: [59] (c) 6XXX (PM, TiH 2 ) steel MP: [57] M: [60] (d) open cell foam 1XXX MSP : [61] T …”

Section: Productionmentioning

confidence: 99%

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Aluminium Foam Sandwich Panels: Manufacture, Metallurgy and Applications

Banhart

Seeliger²

2008

Adv Eng Mater

272

139

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Sandwich panels consisting of a highly porous aluminium foam core and aluminium alloy face sheets are manufactured by roll‐bonding aluminium alloy sheets to a densified mixture of metal powders – usually Al‐Si or Al‐Si‐Cu alloys with 6–8% Si and 3–10% Cu – and titanium hydride, and foaming the resulting three‐layer structure by a thermal treatment. We review the various processing steps of aluminium foam sandwich (AFS) and the metallurgical processes during foaming, compare the process to alternative ways to manufacture AFS, e.g. by adhesive bonding, and give an overview of the available literature. Two ways to treat AFS after foaming are presented, namely forging and age‐hardening. Some current and potential applications are described and the market potential of AFS is assessed.

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Section: Productionmentioning

confidence: 99%

“…C-type) segments by manual TIG welding. [56] The resulting cone, see Fig. 10, is almost 4 m wide at the base and weighs 180 kg.…”

Section: Ariane 5 Rocket Adaptor Prototypementioning

confidence: 99%

Aluminium Foam Sandwich Panels: Manufacture, Metallurgy and Applications

Banhart

Seeliger²

2008

Adv Eng Mater

272

139

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“…con aluminio extruido, hojas de aluminio y estructuras de aluminio de alma alveolar [63] . Las espumas de aluminio son un material prometedor para este tipo de estructuras.…”

Section: a Ap Pl LI Ic Ca Ac Ci Io On Ne Es Sunclassified

Aluminium foams. Manufacture, properties and applications

Gutiérrez-Vázquez¹,

Oñoro²

2008

Rev. metal.

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E Es sp pu um ma as s d de e a al lu um mi in ni io o. . F Fa ab br ri ic ca ac ci ió ón n, , p pr ro op pi ie ed da ad de es s y y a ap pl li ic ca ac ci io on ne es s ( (• •) ) J.A. Gutiérrez-Vázquez * y J. Oñoro * R Re es su um me en n Las espumas de aluminio son materiales porosos que tienen una relevante combinación de propiedades físicas y mecánicas, tales como alta rigidez conjuntamente con un peso específico muy bajo. En este artículo se revisan la estructura, los procesos de fabricación y las propiedades físicas, químicas y mecánicas, así como las aplicaciones de las espumas de aluminio. Los procesos de fabricación se han clasificado atendiendo al estado de agregación en el cual se procesa el metal. El aluminio fundido puede espumarse, directamente, por inyección directa de gas o por la adición de agentes espumantes. Indirectamente, puede conseguirse la espumación llevando a fusión componentes procesados por sinterizado que tienen en su interior un agente espumante. Puede conseguirse la espumación de piezas sinterizadas en estado sólido por espumación de un gas inerte mediante tratamiento térmico. También, es posible obtener espumas de aluminio por electrodeposición o por deposición en fase vapor. En la segunda parte de este trabajo se analizan las propiedades físicas, químicas y mecánicas de las espumas de aluminio, así como las diferentes formas de caracterización. Por último, se detallan las aplicaciones de las espumas de aluminio, dividiéndolas en función de los diferentes sectores industriales. P Pa al la ab br ra as s c cl la av ve eEspumas de aluminio; Espumación; Precursor; Agente espumante; Porosidad.A Al lu um mi in ni iu um m f fo oa am ms s. . M Ma an nu uf fa ac ct tu ur re e, , p pr ro op pe er rt ti ie es s a an nd d a ap pp pl li ic ca at ti io on ns s A Ab bs st tr ra ac ct t Aluminium foams are porous materials to have many interesting combinations of physical and mechanical properties, such as high stiffness in conjunction with very low specific weight. The aluminium foam structure, manufacture processes, physical, chemical and mechanical properties and applications are reviewed in this paper. The various manufacturing processes are classified according to the state of matter in which the metal is processed. Liquid aluminium can be foamed directly by injecting gas or gas-releasing blowing agents. Indirect methods include melting of powder compacts which contain a blowing agent. An inert gas entrapped in powder compacts can produce aluminium foams in solid state after heat treatment. Electro-deposition or metal vapour deposition also allow for the production of aluminium foams. Physical, chemical and mechanical properties and the various ways for characterising the aluminium foams are reviewed in second section of this paper. Finally, the various application fields for aluminium foams are discussed. They are divided into different industrial sectors. K Ke ey yw wo or rd ds s . I IN NT TR RO OD DU UC CC CI IO ON NEl estudio de la estructura de los materiales y su relación con las propi...

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“…[1,2,9 -11] An alternative and preferable method for manufacturing aluminum foam sandwich (AFS) panels can be roll-cladding of face sheets to a sheet of foamable precursor material, then creating the desired shape in an optimal working step, and finally foaming the entire composite; this method is based on diffusion bonding process. [2,8,12] But this method has two main limitations. One is that a constant component thickness may only be achieved with plane sheets.…”

Section: Introductionmentioning

confidence: 98%

A novel method for manufacturing of aluminum foam sandwich panels

Nabavi

Khaki

2010

Surface & Interface Analysis

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In this study, a novel method for manufacturing aluminum foam sandwich (AFS) panels via self-propagating high temperature synthesis (SHS) has been introduced and investigated. In this method, a powder mixture of metallic aluminum and copper oxide was placed in core-sheet interface. Sandwich panel was then heated under static pressure. During heating, SHS reaction (3CuO + 2Al = Al 2 O 3 + 3Cu, H < 0) occurred in the interface. The generated heat from this exothermic reaction caused sheets to join the core by melting the interface and nearby. In order to evaluate the shear strength of the interface, the shear test was applied on manufactured sandwich panels, and its results were compared with those obtained from testing the sandwich panels which were produced by diffusion bonding process. Furthermore, by the aid of energy dispersive spectrometer (EDS) and X-ray diffraction (XRD) analyses, the formation of copper in the core-sheet interface and its diffusion into the sheets and the core were investigated. In addition, by plotting the hardness values of the panels' sheets across distance, it was found that the generated heat of the exothermic reaction caused a local melting of the panel sheets and the core. These results approved that core to sheet joining in metal foam sandwich panels took place because of the SHS reaction. Significantly, this new method could be applied as a proper and alternative method for production of AFS panels.

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Aluminium foam sandwich structures for space applications

Cited by 85 publications

References 1 publication

Aluminium Foam Sandwich Panels: Manufacture, Metallurgy and Applications

Aluminium Foam Sandwich Panels: Manufacture, Metallurgy and Applications

Aluminium foams. Manufacture, properties and applications

A novel method for manufacturing of aluminum foam sandwich panels

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