Journal of Materials Science

, Volume 49, Issue 1, pp 79–87

Aluminum integral foam castings with microcellular cores by nano-functionalization

Authors

    • Chair of Metals Science and Technology, Department of Materials Science and EngineeringUniversity of Erlangen-Nuremberg
  • Christina Blümel
    • Institute of Particle Technology, Department of Chemical and Biological EngineeringUniversity of Erlangen-Nuremberg
  • Stefan Ernst
    • Chair of Metals Science and Technology, Department of Materials Science and EngineeringUniversity of Erlangen-Nuremberg
  • Tobias Fiegl
    • Chair of Metals Science and Technology, Department of Materials Science and EngineeringUniversity of Erlangen-Nuremberg
  • Karl-Ernst Wirth
    • Institute of Particle Technology, Department of Chemical and Biological EngineeringUniversity of Erlangen-Nuremberg
  • Carolin Körner
    • Chair of Metals Science and Technology, Department of Materials Science and EngineeringUniversity of Erlangen-Nuremberg
Article

DOI: 10.1007/s10853-013-7668-z

Cite this article as:
Hartmann, J., Blümel, C., Ernst, S. et al. J Mater Sci (2014) 49: 79. doi:10.1007/s10853-013-7668-z
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Abstract

The goal of the present work is the refinement of the pore morphology of aluminum integral foam castings. Integral foam molding, a modified high pressure die casting process, is used where a mixture of melt and blowing agent particles (magnesium hydride, MgH2) is injected at high velocity into a permanent steel mold. At the mold surface, decomposition of the blowing agent and pore formation is suppressed due to the high solidification rate whereas solidification of the core is much slower allowing blowing agent decomposition, pore nucleation, and growth. Blowing agent particles not only act as gas suppliers but also represent pore nuclei. Thus, microcellular foam cores can be attained by increasing the number of MgH2 particles. But increasing the number of powder particles by powder milling strongly decreases the flowability and strong particle agglomeration as a result of the increasing cohesive forces leads to inhomogeneous foams. Flowability of the powder can be restored by coating it with SiO2-nano-particles resulting in a homogeneous microcellular foam morphology.

Copyright information

© Springer Science+Business Media New York 2013