Novel manufacturing process of closed-cell aluminum foam by accumulative roll-bonding

Kitazono, Koichi; Satô, Eiichi; Kuribayashi, Kazuhiko

doi:10.1016/j.scriptamat.2003.10.035

Cited by 95 publications

(52 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…1,2) Various types of processes have been developed for fabricating porous aluminum including the ALPORAS process, 3) the Lotus-type process 2) and the precursor method. [4][5][6][7][8][9][10][11] A precursor method has high potential for obtaining highporosity and high-quality (i.e., a uniform pore size distribution with highly spherical pores) closed-cell porous aluminum. In the precursor method, aluminum alloy (as a starting material) and a blowing agent powder are first mixed.…”

Section: Introductionmentioning

confidence: 99%

“…Finally, these gases expand the softened aluminum alloy to form porous aluminum. There are several routes for fabricating the precursor, such as the powder metallurgical route, 4,5) the ARB process route 6,7) and the compressive torsion processing route. 8,9) However, various factors prevent their practical application, 1) such as the use of expensive aluminum alloy powder for the starting material and the need for many time-consuming and complicated fabrication processes.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Nondestructive Observation of Pore Structures of A1050 Porous Aluminum Fabricated by Friction Stir Processing

et al. 2010

View full text Add to dashboard Cite

In the automotive industry, porous aluminum is expected to be used as a new functional material because of its light weight, high energy absorption and high sound-insulating property. Recently, a new processing route for fabricating the porous aluminum precursor, which utilizes friction stir processing (FSP), has been developed. It is expected that, by applying the FSP route precursor method, the cost-effective fabrication of porous aluminum with high productivity can be realized. In this study, two different types of A1050 porous aluminum were fabricated from two different sizes of precursor by the FSP route precursor method. The two types of porous aluminum fabricated using small and large precursors are hereafter referred to ''FSP-S porous aluminum'' and ''FSP-L porous aluminum'', respectively. The pore structures of FSP-S porous aluminum, FSP-L porous aluminum and also commercially available porous aluminum (ALPORAS, fabricated by Shinko Wire Co., Ltd.) were nondestructively observed by X-ray computed tomography (X-ray CT). From the nondestructive observation of pore structures, it was shown that a large number of pores of smaller area and volume were distributed in porous aluminum fabricated by the FSP route precursor method compared with the pores in ALPORAS. However, there was little difference in the circularity of pores between porous aluminum fabricated by the FSP route and ALPORAS, and there was little dependence of the pore structure on the precursor size for porous aluminum fabricated by the FSP route. This result indicates the potential of the FSP route for fabricating larger porous aluminum samples.

show abstract

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Nondestructive Observation of Pore Structures of A1050 Porous Aluminum Fabricated by Friction Stir Processing

et al. 2010

View full text Add to dashboard Cite

show abstract

“…On the other hand, in the foaming method that utilizes a liquid state, an injection gas or a gas-releasing foaming agent is used to foam a liquid metal. Aluminum foam, which is one of the most well known foamed metals, [8][9][10][11][12][13][14][15] is manufactured by two methods. One of the methods is direct foaming.…”

Section: Introductionmentioning

confidence: 99%

“…The other method is indirect foaming. 14,15) In this method, a solid precursor is first prepared using uniformly dispersed mixed powders consisting of a metal and foaming agent. Then, the precursor is heated, and it expands and foams as the metal matrix melts.…”

Section: Introductionmentioning

confidence: 99%

Development of a New Method for Manufacturing Iron Foam Using Gases Generated by Reduction of Iron Oxide

et al. 2007

View full text Add to dashboard Cite

A new method for manufacturing iron foam using CO and CO 2 as foaming gases was studied. This method consists of three stages: (1) mixing powders of pure iron, graphite, and hematite; (2) preparing the precursor by cold pressing the mixed powders; and (3) foaming by heating the precursor at temperatures between the liquidus and solidus in the Fe-C binary system. Molten iron containing carbon is foamed by gases generated by a reduction reaction. Optimizations of both the composition of the precursor and the heating conditions are required to produce the iron foam with high porosity. It was found that the content and powder size of hematite in the precursor significantly affect the porosity and pore diameter of the iron foam. Iron foam with a porosity of 55% and average pore diameter of around 500 mm is obtained by heating the precursor of Fe-3.1 mass%C-1.0 mass%Fe 2 O 3 at 1543 K.

show abstract

“…Recently, the authors proposed a new manufacturing process for closed-cell aluminum foams, which is named the accumulative roll-bonding (ARB) process. 4,5) It is noted that the original ARB process has been developed for severe plastic deformation. 6) A schematic illustration of the ARB process is shown in Fig.…”

Section: Introductionmentioning

confidence: 99%

Superplastic Forming and Foaming of Cellular Aluminum Components

Kitazono

2006

Mater. Trans.

View full text Add to dashboard Cite

Liquid and semi-solid state foaming processes have been widely used as a manufacturing method of closed-cell metal foams. These metal foams usually have large pores as well as high porosity. Large pores and inhomogeneous pore distribution often cause a decrease in mechanical properties. Therefore, microcellular foams are desirable for engineering applications. In the present study, solid-state foaming process under superplastic conditions is examined in order to manufacture microcellular aluminum foams. The superplastic flow during the high temperature foaming accelerates the foaming rate and increases the porosity. Commercial SP5083 aluminum alloy sheets were used as a starting material because they are typical superplastic material. Preform sheet containing titanium hydride particles was produced through accumulative rollbonding (ARB) processing. Heating the preform sheet under superplastic conditions, we obtained aluminum foam with small oblate pores. The thermal conductivity was quite small because of the oblate pore shape. Superplastic flow enabled to produce a thin sandwich panel and porous bulge structures. These panel and bulge with oblate spheroidal pores parallel to the surface are industrially important because of their excellent thermal insulation. Present experimental results of superplastic forming and foaming (SPFF) processing has potential for near net-shape forming of microcellular aluminum foams.

show abstract

Novel manufacturing process of closed-cell aluminum foam by accumulative roll-bonding

Cited by 95 publications

References 10 publications

Nondestructive Observation of Pore Structures of A1050 Porous Aluminum Fabricated by Friction Stir Processing

Nondestructive Observation of Pore Structures of A1050 Porous Aluminum Fabricated by Friction Stir Processing

Development of a New Method for Manufacturing Iron Foam Using Gases Generated by Reduction of Iron Oxide

Superplastic Forming and Foaming of Cellular Aluminum Components

Contact Info

Product

Resources

About