Journal of Materials Science

, Volume 49, Issue 1, pp 79–87 | Cite as

Aluminum integral foam castings with microcellular cores by nano-functionalization

  • Johannes Hartmann
  • Christina Blümel
  • Stefan Ernst
  • Tobias Fiegl
  • Karl-Ernst Wirth
  • Carolin Körner


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.


Foam Fumed Silica MgH2 Aluminum Foam Milled Powder 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.



The authors acknowledge the financial support of the Deutsche Forschungsgemeinschaft (DFG), Grant No. KO 1984/5-2.


  1. 1.
    Körner C, Singer RF (2000) Adv Eng Mater 2:159CrossRefGoogle Scholar
  2. 2.
    Nosko M, Simančik F, Florek R (2010) Mater Sci Eng, A 527:5900CrossRefGoogle Scholar
  3. 3.
    Bin J, Zejun W, Naiqin Z (2007) Scr Mater 56:169CrossRefGoogle Scholar
  4. 4.
    Andrews EW, Gioux G, Onck P, Gibson LJ (2001) Int J Mech Sci 43:701CrossRefzbMATHGoogle Scholar
  5. 5.
    Wen CE, Yamada Y, Shimojima K, Chino Y, Hosokawa H, Mabuchi M (2004) Mater Lett 58:357CrossRefGoogle Scholar
  6. 6.
    García-Moreno F, Mukherjee M, Solórzano E, Banhart J (2010) Int J Mater Res 101:1134CrossRefGoogle Scholar
  7. 7.
    Körner C, Hirschmann M, Bräutigam V, Singer RF (2004) Adv Eng Mater 6:385CrossRefGoogle Scholar
  8. 8.
    Körner C (2008) Integral foam molding of light metals: technology, foam physics and foam simulation. Springer-Verlag, Berlin, HeidelbergGoogle Scholar
  9. 9.
    Hartmann J, Trepper A, Körner C (2011) Adv Eng Mater 13:1050CrossRefGoogle Scholar
  10. 10.
    Linsenbühler M, Wirth K-E (2005) Powder Technol 158:3CrossRefGoogle Scholar
  11. 11.
    Campbell C, Keaveny B (2011) In: Houson I (ed) Process understanding: for scale-up and manufacture of active ingredients. Wiley-VCH, WeinheimGoogle Scholar
  12. 12.
    Körner C, Arnold M, Singer RF (2005) Mater Sci Eng, A 396:28CrossRefGoogle Scholar
  13. 13.
    Stanzick H, Wichmann M, Weise J, Helfen L, Baumbach T, Banhart J (2002) Adv Eng Mater 4:814CrossRefGoogle Scholar

Copyright information

© Springer Science+Business Media New York 2013

Authors and Affiliations

  • Johannes Hartmann
    • 1
  • Christina Blümel
    • 2
  • Stefan Ernst
    • 1
  • Tobias Fiegl
    • 1
  • Karl-Ernst Wirth
    • 2
  • Carolin Körner
    • 1
  1. 1.Chair of Metals Science and Technology, Department of Materials Science and EngineeringUniversity of Erlangen-NurembergErlangenGermany
  2. 2.Institute of Particle Technology, Department of Chemical and Biological EngineeringUniversity of Erlangen-NurembergErlangenGermany

Personalised recommendations