X-ray Radiography Inspection of Pores of Thin Aluminum Foam during Press Forming Immediately after Foaming

Hangai, Yoshihiko; Kawato, Daisuke; Ohashi, Masataka; Ando, Mizuki; Ogura, Takuya; Morisada, Yoshiaki; Fujii, Hidetoshi; Kamakoshi, Yuichiroh; Mitsugi, Hironao; Amagai, Kenji

doi:10.3390/met11081226

Cited by 9 publications

(4 citation statements)

References 27 publications

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“…To obtain a shape suitable for friction welding, the aluminum foam was pressed immediately after foaming to prepare a flat aluminum foam (10 mm in thickness). The foamed aluminum can be formed into a flat shape without fracturing pores by pressing immediately after foaming before the temperature of the foamed aluminum drops below the liquidus temperature [47][48][49]. The surface of the pressed aluminum foam was milled to remove 1.2 mm-1.6 mm to expose the pores because the pressed aluminum foam had a dense skin layer on the surface.…”

Section: Aluminum Foam Fabrication Methodsmentioning

confidence: 99%

Friction Welding of Polycarbonate Plate and Aluminum Foam Fabricated by Precursor Foaming Process

Hangai,

Yamamoto,

Goto

et al. 2023

Metals

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Aluminum foam is expected to be one of the candidates for lightweight materials for structural components as it is lightweight and has excellent shock absorption and sound absorption properties. However, aluminum foam has low tensile and flexural strength due to its thin cell walls. Therefore, aluminum foam is used by combining with dense materials. In particular, with the recent trend toward multi-materials, research on the combination with lightweight resins is expected. In this study, we attempted to join aluminum foam fabricated by the precursor method to a thermoplastic resin polycarbonate (PCTA) plate by friction welding. It was found that the aluminum foam and PCTA plate can be joined in about 1 min by friction welding, by rotating the aluminum foam at 2000 rpm and pressing 1 mm into the PCTA plate. In addition, in the friction welding of aluminum foam and PCTA plate, it was found that the pores of the aluminum foam were maintained without being collapsed. The anchoring effect is presumably caused by the penetration of PCTA softened by the frictional heat generated by the friction welding into the pores. Furthermore, tensile tests of the joined samples showed that fracture occurred either at the joining interface or at the base material of the aluminum foam, and that the joining strength was equivalent to the tensile strength of the aluminum foam itself.

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Section: Aluminum Foam Fabrication Methodsmentioning

confidence: 99%

Friction Welding of Polycarbonate Plate and Aluminum Foam Fabricated by Precursor Foaming Process

Hangai,

Yamamoto,

Goto

et al. 2023

Metals

Self Cite

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“…The effect on foaming was also investigated by foaming the fabricated precursor using optical heating. Optical heating [17][18][19] was used because the foaming was affected by the traversing speed of the lower tool when the foaming was performed by the lower tool in the same process as the precursor fabrication.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Precursor by Consolidating Aluminum Alloy Powder Using Friction Stir Welding and Its Foaming

Hangai

Morohashi

Mitsugi

2022

Metals

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In this study, we fabricated a precursor by FSW using ADC12 (Al-Si-Cu alloy) powder and foamed the obtained precursor by optical heating to fabricate the porous aluminum (Al). If ADC12 powder can be used for fabricating the precursor, it is expected that Al waste materials from the manufacturing of industrial products, such as Al cutting scraps, can be used as recycled Al chips, with which the cost of porous Al manufacturing can be reduced. The results demonstrated that ADC12 powder can be consolidated as well as the blowing agent (titanium hydride) and stabilization agent (alumina) powders can be mixed into the consolidated ADC12 by FSW to fabricate precursors at the tool traversing speed v = 10–50 mm/min. In addition, the obtained precursor can be foamed by optical heating. It was also found that the precursor with fewer cracks and defects can be obtained at v = 10, 20, and 30 mm/min versus at v = 40 and 50 mm/min. As a result, porous Al with relatively good pore structures was obtained at v = 10–30 mm/min.

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“…However, such an approach does not provide information on how the deformation of internal structure influences the overall mechanical response of an APM foam element. A possible solution is the use of advanced radiographical imaging methods to reveal the deformation processes within the microstructure of the specimen during a loading procedure [ 3 , 20 , 21 , 22 ]. Herein, the time-resolved 4D µCT experiments based on in-situ loading of a specimen in the X-ray scanner that is used for its simultaneous imaging enables capturing the deforming microstructure of the observed APM sample.…”

Section: Introductionmentioning

confidence: 99%

Fast 4D On-the-Fly Tomography for Observation of Advanced Pore Morphology (APM) Foam Elements Subjected to Compressive Loading

et al. 2021

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Observation of dynamic testing by means of X-ray computed tomography (CT) and in-situ loading devices has proven its importance in material analysis already, yielding detailed 3D information on the internal structure of the object of interest and its changes during the experiment. However, the acquisition of the tomographic projections is, in general, a time-consuming task. The standard method for such experiments is the time-lapse CT, where the loading is suspended for the CT scan. On the other hand, modern X-ray tubes and detectors allow for shorter exposure times with an acceptable image quality. Consequently, the experiment can be designed in a way so that the mechanical test is running continuously, as well as the rotational platform, and the radiographic projections are taken one after another in a fast, free-running mode. Performing this so-called on-the-fly CT, the time for the experiment can be reduced substantially, compared to the time-lapse CT. In this paper, the advanced pore morphology (APM) foam elements were used as the test objects for in-situ X-ray microtomography experiments, during which series of CT scans were acquired, each with the duration of 12 s. The contrast-to-noise ratio and the full-width-half-maximum parameters are used for the quality assessment of the resultant 3D models. A comparison to the 3D models obtained by time-lapse CT is provided.

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X-ray Radiography Inspection of Pores of Thin Aluminum Foam during Press Forming Immediately after Foaming

Cited by 9 publications

References 27 publications

Friction Welding of Polycarbonate Plate and Aluminum Foam Fabricated by Precursor Foaming Process

Friction Welding of Polycarbonate Plate and Aluminum Foam Fabricated by Precursor Foaming Process

Fabrication of Precursor by Consolidating Aluminum Alloy Powder Using Friction Stir Welding and Its Foaming

Fast 4D On-the-Fly Tomography for Observation of Advanced Pore Morphology (APM) Foam Elements Subjected to Compressive Loading

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