Comparative study of stir casting and infiltration casting of expanded glass-aluminium syntactic foams

Broxtermann, S.; Su, Mingming; Hu, Hao; Fiedler, Thomas

doi:10.1016/j.jallcom.2020.155415

Cited by 25 publications

(18 citation statements)

References 36 publications

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“…Therefore, the cost reduction in CMFs is a logic and reasonable aim. For that purpose, different filler materials have been applied to produce CMFs, like expanded perlite (Ref [28][29][30][31][32], expanded glass (Ref [33][34][35][36][37] or expanded clay (Ref 38 -42). Expanded perlite is polygonal; therefore, the structure is loaded by strong stress concentrators.…”

Section: Introductionmentioning

confidence: 99%

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Orbulov

Szlancsik

Kemény

et al. 2022

J. of Materi Eng and Perform

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This paper is dealing with the production and investigation (structural and mechanical) of composite metal foams (CMFs) with AlSi9MgMn matrix and ~60 vol% of different nominal diameter light expanded clay particles (LECPs) filler. The main aim was to produce a cheap CMF grade for automotive industry. The samples were produced by liquid state low pressure infiltration. Cubic samples were manufactured from the produced CMF blocks for structural (optical microscopy, scanning electron microscopy and energy-dispersive x-ray spectrometry (EDS)) and for mechanical (compression) investigations and tests. The CMFs were investigated in as-cast and in T6 heat-treated conditions. The macrostructural investigations showed homogenous structure and sufficient quality infiltration. On the microscopic scale, the EDS investigations revealed a complex interface layer affected by chemical reactions between the matrix material and the filler particles. The compressive test proved the classic foam-like mechanical behavior of the CMFs (with long plateau region). A relationship (valid for both the as-cast and T6 heat-treated conditions) was found between the characteristic properties and the nominal diameter of the filler. Based on these results, the LECPs filled CMFs are ideal candidates for automotive applications with tailorable properties.

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Section: Introductionmentioning

confidence: 99%

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Orbulov

Szlancsik

Kemény

et al. 2022

J. of Materi Eng and Perform

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“…The research team found that even though foam density was 2 g/cm 3 , the compressive strength was high and limited strain hardening effect was seen in the plateau region. Broxtermann et al 31 compared stir-casting and infiltration casting methods for aluminum syntactic fabrication. As a result of their work, the researchers reported that although infiltrated foams displayed vertical density gradient, this case was not valid for stir casted foams.…”

Section: Introductionmentioning

confidence: 99%

An Investigation on the Effect of Heat Treatment on the Compression Behavior of Aluminum Matrix Syntactic Foam Fabricated by Sandwich Infiltration Casting

2021

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In this research, syntactic foams including Al-7075 matrix and 2-4 mm low-cost pumice particles were manufactured via a novel casting method called as sandwich infiltration. According to physical evaluations, thanks to extremely porous structure of pumice, density values of the fabricated foams varied between 1.42 and 1.61 g/cm 3. Porosity values were between 40.62% and 47.39%. Microstructural observations showed that there was a perfect infiltration between Al matrix and pumice particles because of correct process optimization (process pressure of 0.1 MPa, matrix melting temperature of 720°C and filler pre-temperature of 500°C). Furthermore, T6 treatment was applied to samples to comprehend effect of the aging on mechanical properties. The results indicated that there was an affirmative relation between the heat treatment and quasi-static compressive properties of the fabricated foams. The highest compressive strength, plateau stress and energy absorption values were measured as 64.4 MPa, 74.3 MPa and 34 MJ/m 3 for heat treated samples. It was also observed that although the highest energy efficiency of 0.89 was calculated for heat treated sample, there was no relation between the heat treatment and efficiency. As for failure modes, as-cast samples exhibited ductile barreling characteristic whereas T6 treated foams indicated brittle v-shape fracture.

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“…Broxtermann et al. 34 compared stir casting and pressure infiltration casting methods in terms of their effects on the mechanical properties of expanded glass filled aluminum syntactic foams and they found that stir casting foams had higher mechanical strength than infiltration casting foams. Szlancsik et al.…”

Section: Introductionmentioning

confidence: 99%

“…The research team pointed out that fabricated foams having 2 gr/cm 3 density displayed syntactic characteristics with three different deformation regions under the compressive loading. Broxtermann et al 34 compared stir casting and pressure infiltration casting methods in terms of their effects on the mechanical properties of expanded glass filled aluminum syntactic foams and they found that stir casting foams had higher mechanical strength than infiltration casting foams. Szlancsik et al 35 investigated mechanical responses of expanded clay reinforced AlSi10MnMg foams and indicated that heat-treated samples exhibited higher yield strength and energy absorption.…”

Section: Introductionmentioning

confidence: 99%

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

Bolat

Ergene

Karakılınç

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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On the road to real applications, although there are lots of efforts focusing on mechanical and physical features in the literature, their machining abilities were examined in a very limited manner. In this study, machining properties of pumice reinforced AA7075 syntactic foams manufactured via the newly offered sandwich infiltration technique were investigated by performing face turning. Physical and microstructural (optical and SEM works) analyses were conducted on fabricated foams to carry out sample characterization. All machining forces were measured for different cutting speeds (25, 50, and 100 m/min) and feed rates (0.05, 0.10, and 0.15 mm/rev). After the turning operation, areal surface roughness values were measured using a 3D surface profilometer and material removal rate (MRR) values were calculated. Besides, chip mixtures including pumice and metal fragments were collected to probe chip morphology in detail. The results showed that machining forces were affected by the operation parameters differently, and the lowest surface roughness was detected at the cutting speed of 100 m/min and 0.05 mm/rev feed rate. Furthermore, the shape of the metal chips changed from long/continuous characteristic to saw-tooth morphology depending on increasing cutting speed levels while pumice particles exhibited breakaway tendency as the feed rates went up.

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Comparative study of stir casting and infiltration casting of expanded glass-aluminium syntactic foams

Cited by 25 publications

References 36 publications

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

Low-Cost Light-Weight Composite Metal Foams for Transportation Applications

An Investigation on the Effect of Heat Treatment on the Compression Behavior of Aluminum Matrix Syntactic Foam Fabricated by Sandwich Infiltration Casting

Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam

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