Injection Molded Plastics with Aluminum Foam Core

Effects of chemical composition on the pore structure and heat treatment on the deformation of PM aluminium foams 6061 and 7075

“…Obtained records were used for the evaluation of the deformation behaviour and energy absorption ability of foam. Energy absorption ability was calculated from the region under the load-deflection curve, and the plateau length was determined in the region of the last stress drop in the area next to densification part [7].…”

“…The porous structure of closed cell aluminium foams offers the ability to absorb kinetic energy at nearly constant stress in wide deformation range [1][2][3][4][5]. Aluminium foams made via the powder metallurgical route (PM) with surface skin have better mechanical properties like compression strength than opencell aluminium foam, and aluminium foam prepared via melting route [2][3][4][6][7][8].…”

“…The porous structure of closed cell aluminium foams offers the ability to absorb kinetic energy at nearly constant stress in wide deformation range [1][2][3][4][5]. Aluminium foams made via the powder metallurgical route (PM) with surface skin have better mechanical properties like compression strength than opencell aluminium foam, and aluminium foam prepared via melting route [2][3][4][6][7][8]. Therefore PM aluminium foam is more recommended for industrial and automotive applications, as it is possible very effectively to produce 3D complex shape parts which led to first industrial applications (developed at IMMM SAS, Bratislava) of PM aluminium foams in Ferrari Modena 360 (stiffener of side rail, 6,000 pcs year −1 ), Audi Q7 (crash box against rare impact, 120,000 pcs year −1 ) and Siemens and Bombardier light trains (bumper of railway carriages, 1,000 pcs year −1 ) [9].…”

“…Effect of different chemical composition and ways of heat treatment of AA7XXX on compression strength and absorption ability was studied and also fracture surface of cell walls before and after heat treatment of aluminium foam was observed [11,23]. The stress-strain behaviour of foams is very sensitive and determined by the properties of the cell wall material: hardness, strength, the thickness of cell walls and surface skin [7,8,17,18,23].…”

Production of aluminium casting with open-cell aluminium foam core

“…Most metal foam cores currently used in castings are closed cell type due to simple manufacture. Even metal integral foam with closed cell metal core can avoid penetration of molten metal or adhesive into the porous structure when making surface skin on the core, the drawbacks of the closed cell foam core are non-uniform structure (Kennedy, 2012;Körner et al, 2006) and cracks created during the solidification of the foam (Florek et al, 2014). The lack of control metal foam core structure results in unpredictable properties of final casting products.…”