Materials and Technologies for Lightweight Design WORKSHOP ON RECENT DEVELOPMENTS IN THE WORLD OF ENGINEERING MATERIALS, Smolenice,

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1 NEW TRENDS IN MANUFACTURING OF PM ALUMINIUM FOAMS Fero Simančík Roman Florek Martin Nosko Peter Tobolka Jaroslav Jerz Jaroslav Kováčik speaker Institute of Materials & Machine Mechanics Slovak Academy of Sciences, Bratislava Materials and Technologies for Lightweight Design WORKSHOP ON RECENT DEVELOPMENTS IN THE WORLD OF ENGINEERING MATERIALS, Smolenice,

2 Institute of Materials & Machine Mechanics, Slovak Academy of Sciences is since 1993 involved in development of aluminium foams and their prototyping Main industrial partners: Al-powder compact foaming ALPORAS - prototypes More than hundred prototypes developed and tested

3 Competitive solutions Profile made from Al-foam Simple profile made from Al light weight (comparable) high stiffness to weight ratio (profile is better in one axis, foam structure is isotropic)

4 Car body separation wall made of Al foam Courtesy of LKR Mg die casting (Daimler-Crysler)

5 Although the foam prototypes have shown good performance, obtained benefits are usually too expensive if the foam is only space holder

6 Possible solutions: 1. Improve properties, keep the price 2. Reduce manufacturing costs 3. Add additional functions Action 15 per kg!!! 6 per liter!!!

7 How to improve properties keeping the costs? 1. Avoid inefficient use (mostly as filler) - component properties are controlled by bulk part - foam costs increases total component price use complex shape foam with surface skin foam as natural sandwich (without integration into bulk part)

8 Reduction of foam costs? : 1. High costs of compacted powder precursor (~70% of total component costs ) reduce costs of expensive precursor material reduce use of expensive precursor material 2. Lack of reliable modeling and simulation for 3D foam components with skin - necessity of shape iteration and optimisation of properties via experimental testing on prototypes cheap and rapid prototyping

9 Precursor manufacturing Mixture of aluminium powders and TiH 2 powder Cold isostatic pressing of these powders Transport of pressed billets Pre-heating of billets and direct extrusion (scrap about 10% per billet) foaming Transport of foamable precursor replace extrusion by conform

10 CONFORM vs. HOT EXTRUSION Benefits no pre-compaction of powders continual process almost scrap-free no preheating of powder necessary Drawbacks low compaction speed (productivity) limitation in alloys for compaction high investment costs

11 Alternative method Equal Channel Angular Pressing method - ECAP Comparison of direct extrusion vs. ECAP (processing) complex straining simple shear (efficient straining) normal stresses High loads => expensive equipment (high pressing temperature needed) cross-section reduction non- uniform straining through cross-section significantly reduced normal stresses low loads => low cost equipment (i.e. pressing can be done at lower T) no cross-sectional changes Uniform straining

12 Alternative method Equal Channel Angular Pressing method - ECAP Comparison of direct extrusion vs. ECAP (processing) Al powder extruded at 500 C extrusion ratio 11:1 Al powder ECAP-ed at 200 C Angle of ECAP tool = 90 Al powder ECAP-ed at 350 C Angle of ECAP tool = 90 F F Torn up oxides shear plane

13 Alternative method Equal Channel Angular Pressing method - ECAP Foaming ability of ECAP-ed precursor 30 ECAP-tool temperature 300 C 25 Expansion height (mm) pressing immediately after filling the powders into the pre-heated tool no pre-heating of the powders Initial height of the foamed samples Time (s) 20 mm Comparable foaming ability with current extruded precursors

14 Additional price reduction of foamable precursor Input 1 Equal Channel Angular pressing method - ECAP no low Open need lower possibility forces question: temperature => powder pre-compaction no of scrap-free uniform need incorporation life-time pre-heating of compaction shearing high of process of compaction powders investment before into foaming tool compaction into - tool 300 C costs billets line and production speed Molten aluminium Input 2 Foamable precursor ECAP tool 300 C Aluminium powders with foaming agent Foaming machine Feeding screw compacted precursors Output : aluminium foam part

15 Partial substitution of powder with aluminium scrap 1. Aluminium powders + aluminium scrap + foaming agent and/or 2. Aluminium scrap + stabilising particles (oxides, calcium) + foaming agent ECAP tool 300 C Feeding screw compacted precursors Possible due to ECAP process - the price can be decreased even a bit!

16 Partial substitution of powder with aluminium scrap 0. Aluminium scrap + foaming agent 1. Aluminium powders + aluminium scrap + foaming agent and/or 2. Aluminium scrap + stabilising particles (oxides, calcium) + foaming agent Possible due to ECAP process - the price can be decreased even a bit!

17 Partial substitution of powder with aluminium scrap % 6080 chips + 50% foam chips PM precursor AlMg1Si chips expansion [mm] time [s] Longer foaming time (E consumption), lower final foam expansion (lower p), thick surface oxides (no foam stabilisation, must be ruptured prior foaming) but - the price can be decreased even a bit!

18 Partial substitution of foamable precursor by aluminium melt Putting precursor into mould and pre-heating below foaming temperature Pouring the melt on precursor pcs. Instant foaming Melt is a heater, fills space between precursors (no entrapped gases)

19 ~ 50 vol. % melt Foaming time ~ 1 min.

20 Foaming with melt Comparision different portion of foaming agent (0,8 vs. 1,5 wt%) Foamable precursor AlSi10 + 0,8 wt% TiH 2 AlSi10 melt Foamable precursor AlSi10 + 1,5 wt% TiH 2 AlSi10 melt

21 ~ 80 % of melt is converted into foam ~ 40% precursor costs savings rest can be remelted and used again

22 Problems to solve due precursor preheating 0.8 wt.% 1.5 wt.% Structures of precursor after preheating on 580 C, dwell time 5 minutes Different amount of foaming agent It is necessary to avoid an early decomposition of foaming agent

23 Problems to solve due precursor preheating Early decomposition of foaming agent can be overcome using Thermal treatment of foaming agent postpone decomposition up to higher temperatures, some amount of foaming gas is lost Optimisation of dwelling time on preheating temperature (as high as possible) Using optimal amount of foaming agent Using high heat flux into the mould after molten aluminium is poured

24 Moulds for complex parts Toyota Yaris Toyota Landcruiser

25 Yaris wax model

26 Injection of foam into ceramic shell mould

27 Landcruiser - injection of foam into preheated robust ceramic mould

28 Foaming after injection using residual heat in the mould

29 Mould disintegrates on cooling due to thermal inherent stresses

30 Influence of mould preheating

31 Typical injected foamed parts

32 Complex 3 D shape aluminium foam parts can be successfully prepared via rapid prototyping using injection into sustainable ceramic moulds: Low moulding costs Significant shortening of prototype preparation Changes possible without delay Small series possible Reproducible quality Potential to utilise melt (further cost reduction) precursor combination

33 Conclusions The techniques for foaming of aluminium are well developed and allow to manufacture almost all foam shapes and sizes with acceptable quality (and sometimes also acceptable costs) The structure of present foams is stochastic and only partially controllable, but the reproducibility of foam properties is acceptable Even present foam generation has shown an excellent performance in many case studies. However the foams are usually applied inadequately and their potential is exploited insufficiently (benefits are too expensive) The new foam-familiar design is inevitable

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