Relationship between Porosity and Interface Fracture on Aluminum Foam Sandwich with Dense Steel Face Sheets Fabricated by Friction Stir Processing Route

Abstract

An aluminum foam sandwich consisting of an aluminum foam core with two dense metallic face sheets is expected to be used as a lightweight structural component with good energy and vibration absorption properties. In this study, by the friction stir processing route, aluminum foam sandwiches with porosity of approximately 5585% and metallurgical bonding between the aluminum foam and dense steel sheets were successfully fabricated. Moreover, tensile tests were carried out on the fabricated aluminum foam sandwiches. Through the test results, it was shown that, although a brittle intermetallic compound layer exists at the interface, fracture in the aluminum foam part with porosity above 65% occurs and the bonding strength of the interface is higher than the tensile strength of the aluminum foam.

Fabrication and Tensile Property of Sandwich Panel with ADC12 Foam Core by Friction Stir Processing Route

“…(この方法を摩擦攪拌法と呼ぶ) 11,12) を提案した．この方法で は，アルミニウム板中への添加剤粉末の攪拌・混合により作 製するプリカーサと，表面材となる緻密板材の接合を同時に 行うことが可能である 13,14) ．そこで，この利点を活用して， 緻密鋼板とアルミニウムフォームのコアを接合したサンドイ ッチパネルの作製へ展開を図ってきた 15,16) ．しかしながら， 構造体のより軽量化には，表面材はアルミニウム板材とする り 2400 番 ま で 研 磨 後 ， 粒 径 1.0 mm の ア ル ミ ナ 粉 末 ( a …”

A review of the compressive properties of closed-cell aluminum metal foams

“…26 The further publications on this subject have explained the process in detail and its pros and cons. [27][28][29][30][31][32][33][34][35][36] The various mechanical and structural characterizations of the metal foam produced through the FSP route, using advanced techniques such as X-Ray Computed tomography (XRCT), have been reported in a few publications. 26,29,34,[37][38][39] Images of solid aluminum foam obtained through various techniques are shown in Figure 1.…”

Fabrication of Aluminum Foam Core Sandwich Using Sandwich-Type Foamable Precursor with Two Face Sheets by Friction Stir Welding Route

“…912) In this method, both the production of a foamable precursor by mixing blowing agent powder into Al sheets and metallurgical bonding between the foamable precursor and dense metallic face sheets can be conducted simultaneously; thus, high productivity of the foamable precursor can be realized. Moreover, using this fabrication method, we succeeded in fabricating an AFS comprising an A1050 Al foam core and SPCC low-carbon steel face sheets 9,10) and an AFS comprising an ADC12 Al alloy foam core and dense Al face sheets. 11,12) In the fabrication of the AFS, a foaming process, in which two foamable precursors with one face sheet placed face to face in a die are heated and the Al foam core is formed by bonding two foaming precursors, has been used.…”