Fabrication of functionally graded aluminum foam using aluminum alloy die castings by friction stir processing

Hangai, Yoshihiko; Takahashi, Kazuya; Utsunomiya, Takao; Kitahara, Soichiro; Kuwazuru, Osamu; Yoshikawa, Nobuhiro

doi:10.1016/j.msea.2011.11.100

Cited by 109 publications

(43 citation statements)

References 12 publications

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“…Details of the FSP procedure for fabricating precursors have been described elsewhere. 11,14) Briefly, two plates were stacked with alumina powder (¡-Al 2 O 3 , ³1 µm) distributed between them as the stabilization agent. The amount of alumina used was 5 mass% of the mass of the aluminum alloy with dimensions of the area over which alumina was distributed and the length of the tool probe.…”

Section: Express Regular Articlementioning

confidence: 99%

“…There are several routes for fabricating the precursor, namely, the powder metallurgical (P/M) route, 25) accumulative rollbonding (ARB) route, 6,7) compressive torsion processing route 8,9) and friction stir processing (FSP) route. 10,11) Recently, an FSP route that does not require the use of a blowing agent for fabricating the precursor has been developed. 1214) In this process, aluminum alloy highpressure die castings, which contain a large number of gas pores, 15,16) are used as starting materials for the fabrication of aluminum foams.…”

Section: Introductionmentioning

confidence: 99%

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Effects of Porosity and Pore Structure on Compression Properties of Blowing-Agent-Free Aluminum Foams Fabricated from Aluminum Alloy Die Castings

et al. 2012

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Aluminum foam was fabricated without the use of a blowing agent by a friction stir processing route using ADC12 aluminum alloy die castings, which contain a large number of gas pores. In this study, ADC12 foams with a porosity of 5077% were successfully fabricated, and the pore structures and compression properties of the obtained ADC12 foams were investigated. The ADC12 foams had smaller pores than commercially available aluminum foam. Moreover, the pore size of the ADC12 foams was almost the same regardless of the porosity. According to the results of compression tests, the plateau stress and energy absorption tend to decrease with increasing porosity. Commercially available aluminum foam exhibited higher energy absorption at a low compression stress, whereas the ADC12 foams exhibited higher energy absorption at a high compression stress. Also, the ADC12 foams with higher porosity exhibited higher energy absorption per unit mass, regardless of the compression stress. In contrast, the energy absorption per unit volume was greatest for the low-porosity ADC12 foam at a low compression stress but greatest for the high-porosity foam at a high compression stress.

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Section: Express Regular Articlementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effects of Porosity and Pore Structure on Compression Properties of Blowing-Agent-Free Aluminum Foams Fabricated from Aluminum Alloy Die Castings

et al. 2012

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“…Attempts have been made to form composites of Al foam with denser materials to improve its mechanical properties. 28) For example, filling a hollow frame with Al foam to create a composite structure has been shown to improve the mechanical properties. 35) Moreover, the mechanical properties are further improved by bonding the foam and the frame with each other.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of an Al Foam/Dense Steel Composite by Friction Welding

Hangai

Saito

2013

Mater. Trans.

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Al foam is lightweight with superior shock-absorbing properties but has low tensile and bending strengths. This has spurred efforts to form composites of Al foam with dense materials. In this study, we examined the possibility of fabricating composite structures of Al foam and dense steel with strong metal bonding by employing friction welding. The use of friction welding is expected to facilitate the fabrication of Al foam/ dense steel composites by a simple process with low environmental impact. It is shown that this procedure is capable of fabricating an Al foam/ dense steel composite in which the Al foam completely fills the hollow in the dense steel. An FeAl intermetallic compound (IMC) layer with a thickness on the order of 10 µm was found throughout almost the entire interface between the Al foam and the dense steel. Therefore, it is shown that an Al foam/dense steel composite with strong metal bonding can be fabricated.

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“…13,14) It is considered that the strength of each region can be controlled by controlling the amount and distribution of residual NaCl, for example, by coating the surface of the composite to prevent or delay the removal of NaCl.…”

Section: Relationship Between Amount Of Residual Nacl and Compressivementioning

confidence: 99%

Relationship between Amount of Residual NaCl and Compressive Properties of Porous Al/NaCl Composites Fabricated by Sintering and Dissolution Process

et al. 2013

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In this study, a porous Al/NaCl composite was fabricated by a sintering and dissolution process, and the possibility of controlling the mechanical properties of porous Al by varying the amount and distribution of residual NaCl was investigated. It was shown that the range of the plateau region decreased and the stressstrain curves became similar to those of dense materials as the amount of residual NaCl increased. The deformation started from the layers where NaCl was removed, then the layers where NaCl remained started to deform. This indicates that the strength of each region can be controlled by varying the amount and distribution of residual NaCl.

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Fabrication of functionally graded aluminum foam using aluminum alloy die castings by friction stir processing

Cited by 109 publications

References 12 publications

Effects of Porosity and Pore Structure on Compression Properties of Blowing-Agent-Free Aluminum Foams Fabricated from Aluminum Alloy Die Castings

Effects of Porosity and Pore Structure on Compression Properties of Blowing-Agent-Free Aluminum Foams Fabricated from Aluminum Alloy Die Castings

Fabrication of an Al Foam/Dense Steel Composite by Friction Welding

Relationship between Amount of Residual NaCl and Compressive Properties of Porous Al/NaCl Composites Fabricated by Sintering and Dissolution Process

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