Forming metal foams by simpler methods for cheaper solutions

Abstract

The advantages advanced pore morphology (APM) and a reduction in production complexity are discussed. These two aspects are key to low-cost PM manufacturing of aluminum foam parts. APM approach is based on the separation of the two main steps of the powder metallurgical process for production of metal foam parts, namely foam expansion and part shaping. APM metal foam parts consist of small-volume foam elements joined to each other in a separate process step. It is pointed that with a reduced part price, existing markets could be served with low-cost but high-quality metal foam parts

Experimental Testing of Single APM Spheres

“…Additionally, they provide some distinctive differences between APM and conventional aluminium foams. A practical example of filling a hollow profile with APM elements and comparing the stressstrain diagrams between the hollow profile, hollow profile filled with APM elements and hollow profile filled with bonded APM elements is given in [9,13]. The authors conclude that filling the profile with APM elements increases the capability of energy absorption which can be further improved by bonding the APM elements.…”

“…Their detailed technology concept, production and properties are described in [9,12]. The APM foam parts exhibit two types of porosity: (i) the inner porosity in single APM foam elements and (ii) the porosity between the many APM foam elements [13].…”

The effect of production parameters on the foaming behavior of spherical-shaped aluminum foam

“…Spherical-shaped aluminum foam samples were obtained by means of free-form foaming in our previous studies. Because of the surface tension during foaming process, the precursor samples were put into spherical shape 12 . However, the samples could not get exactly a spherical shape due to the mass of the melted samples.…”

“…But the spherical-shaped metallic foam parts are produced without a mould. They are produced by foaming a precursor material with APM (Advanced Pore Morphology) technology which is developed by IFAM in Germany 12 . This technology consists of two main steps as the foam expansion and the foam shaping.…”

“…These parts are combined with a simple bonding technique ( Figure 1). Therefore, APM foam parts manufacturers provide maximum flexibility for their users 12 . They can be used as team members in front of vehicles by filling inside of steel pipes [13][14][15] .…”