An Experimental Study on Boron Carbide Reinforced Open Cell Aluminum Foams Produced via Infiltration Technique

T. Sunar, M. Cetin

Abstract


Light structures and parts are very effective for new engineering applications. Their considerably low densities, high energy absorption capabilities, and desirable mechanical properties make them useful for particularly automotive, defense and aerospace industries. Besides these positive properties, it is known that the production and processing of cellular materials is very tough and worth the effort. Recently, with advances in new technologies like 3D printing or selective laser melting, now different types of cellular materials can be produced. But manufacturing of metallic foams via casting especially replication or infiltration method is fairly an economic method when compared with other methods. In this study, vacuum-gas infiltration set-up was used to produce B4C reinforced aluminum foams. The mentioned method involves the addition of space holder materials and a dissolution technique to remove them after solidification of the metal. As space holder materials NaCl particles were selected and mixed with B4C powders to produce B4C reinforced A360 aluminum foam. By changing the weight ratio of B4C particles, the alteration of properties like porosity, compression strength, and energy absorption capacity was investigated. Additionally, computer tomography views were obtained to see and interpret the microstructures of the foams. Compression tests were carried out to evaluate the mechanical behavior of the foams under static loading. The porosities of samples obtained as between 65-75%. The compressive strength increased with rising relative density.


Keywords


cellular materials; aluminum foam; space holders; replication

Full Text:

PDF

References


L.J. Gibson, M.F. Ashby, Cellular solids, Pergamon Press Ltd., Cambridge, 1997

J. Banhart, “Manufacture, characterization and application of cellular metals and metal foams”, Progress in Materials Science, Vol. 46, pp. 562–563, 2001

J. Banhart, “Properties and Applications of Cast Aluminum Sponges”, Advanced Engineering Materials, Vol. 2, pp. 188, 2000

R. Goodall, A. Mortensen, “Microcellular aluminum? Child’s play!”, Advanced Engineering Materials, Vol. 9, pp. 951–954, 2007

S.B. Pimiento, M.E. Hernandez-Rojas, M.E. Palomar-Pardave, “Processing and characterization of open-cell aluminum foams obtained through infiltration processes”, Procedia Material Science, Vol. 9, pp. 54–61, 2015

J.F. Despois, A. Marmottant, L. Salvo, A. Mortensen, “Influence of the infiltration pressure on the structure and properties of replicated aluminum foams”, Materials Science and Engineering A, Vol. 462, pp. 68-75, 2007

ASM Handbook, Properties and Selection: Nonferrous Alloys and Special-Purpose Materials, ASM International, Vol. 2 pp. 889-896, 1990

W.M. Haynes, CRC Handbook of Chemistry and Physics, CRC Press LLC, Boca Raton, pp. 89, 2013

L. Polonsky, S. Lipson, H. Markus, “Lightweight Cellular Metals”, Modern Castings, Vol. 39, pp. 57–71, 1961

Q.Z. Wang, C.X. Cui, S.J. Liu, L.C. Zhao, “Open-celled porous Cu prepared by replication of NaCl space-holders”, Materials Science and Engineering A, Vol. 527, pp. 1275-1278, 2010

G.A. Lara-Rodriguez, I.A. Figueroa, M.A Suarez, O. Novelo-Peralta, I. Alfonso, R. Goodall, “A replication casting device for manufacturing open cell Mg foams”, Journal of Materials Processing Technology, Vol. 243, pp. 16–22, 2017

T.G. Nieh, K. Higashi, J. Wadsworth, “Effect of cell morphology on the compressive properties of open-cell aluminum foams”, Materials Science and Engineering A, Vol. 283, pp. 105-110, 2000

F.N. Habib, P. Iovenitti, S.H. Masood, M. Nikzad, “Cell geometry effect on in-plane energy absorption of periodic honeycomb structures”, International Journal of Advanced Manufacturing Technology, Vol. 94, pp. 2369-2380, 2018

F. Caiazzo, S.L. Campanelli, F. Cardaropoli, N. Contuzzi, V. Sergi, A.D. Ludovico, “Manufacturing and characterization of similar to foam steel components processed through selective laser melting”, International Journal of Advanced Manufacturing Technology, Vol. 92, pp. 2121-2130, 2017

A.R. Kennedy, S. Asavavisitchai, “Effects of TiB2 particle addition on the expansion, structure and mechanical properties of PM Al foams”, Scripta Materialia, Vol. 50, pp. 115–119, 2004

A. Uzun, M.Turker, “The investigation of mechanical properties of B4C-reinforced AlSi7 foams”, International Journal of Materials Research, Vol. 106, pp. 970-977, 2015

B. Zhao, A.K. Gain, W. Ding, L. Zhang, X. Li, Y. Fu, “A review on metallic porous materials: pore formation, mechanical properties, and their applications”, The International Journal of Advanced Manufacturing Technology, Vol. 95, pp. 2641-2659, 2018

Y. Conde, J.F. Despois, R. Goodall, A. Marmottant, L. Salvo, C. San Marchi, A. Mortensen , Replication processing of highly porous materials. Advanced Engineering Materials, Vol. 8, pp. 795–803, 2006

T. Sunar, M. Çetin, “Production of Open Cell Aluminum Foam by Vacuum Casting Method”, 8th International Advanced Technologies Symposium, 9, 1905-1909, 2017

I. Standard, Mechanical testing of metals, ductility testing, compression test for porous and cellular metals, Reference Number ISO 13314, pp. 1-7, 2011

J.A. Liu, F. Gao , Y.Q. Rao, C.L. Wu, Y. Liu, “Compressive Properties of Aluminum Foams Produced by Replication Route using Spheroidal Calcium Chloride as Space Holder”, Materials Transactions, Vol. 55, pp. 1906-1908, 2014

C. San Marchi, A. Mortensen, Handbook of Cellular Metals Production, Processing, Applications, (editors, H.P. Degischer, B. Kriszt), Wiley-VCH, pp. 44-56, 2002

U. Ramamurty, A. Paul, “Variability in mechanical properties of a metal foam”, Acta Materialia, Vol. 52, pp. 869–876, 2004

Q. Fabrizio, A. Boschetto, L. Rovatti, L. Santo, “Replication casting of open-cell AlSi7Mg0.3 foams” Materials Letters, Vol. 65, pp. 2558–2561, 2011




eISSN: 1792-8036     pISSN: 2241-4487