Abstract
The unique porous structure of foam metal imparts a variety of advantageous properties, including low weight, reduced density, extensive specific surface area, efficient sound and energy absorption, exceptional thermal insulation, effective electromagnetic shielding, and outstanding electrochemical behavior. As a result, foam metals are deemed crucial for both functionalizing structural materials and structuring functional materials, finding widespread application in electronics, chemicals, machinery, and aerospace sectors. Currently, the welding of foam metals is a subject of significant interest and ongoing research, with numerous studies aimed at refining the welding process. This review provides an overview of the current state-of-the-art research on foam metal welding and evaluates the feasibility of different welding techniques from a methodological perspective. A comparison of the efficiency and efficacy of various welding approaches in the preparation of foam metal joints is performed to highlight their strengths and limitations. Finally, this paper summarizes the current developments in foam metal welding and provides insights into the future trajectory of this field.
Similar content being viewed by others
Data availability
Not applicable.
Code availability
Not applicable.
References
Banhart J, Ashby M, Fleck N (1999) Metal foams and porous metal structures. In: Metal Foams and Porous Metal Structures, vol 56, pp 14–16
Baumgärtner F, Duarte I, Banhart J (2000) Industrialization of powder compact toaming process. Adv Eng Mater 2(4):168–174. https://doi.org/10.1002/(SICI)1527-2648(200004)2:4<168::AID-ADEM168>3.0.CO;2-O
Fusheng H, Zhengang Z (1999) The mechanical behavior of foamed aluminum. J Mater Sci 34(2):291–299. https://doi.org/10.1023/A:1004401521842
Zardiackas LD, Parsell DE, Dillon LD, Mitchell DW, Nunnery LA, Poggie R (2001) Structure metallurgy and mechanical properties of a porous tantalum foam. J Biomed Mater Res 58(2):180–187. https://doi.org/10.1002/1097-4636(2001)58:2<180::AID-JBM1005>3.0.CO;2-5
Imwinkelried T (2007) Mechanical properties of open-pore titanium foam. J Biomed Mater Res A 81(4):964–970. https://doi.org/10.1002/jbm.a.31118
Dinesh BVS, Bhattacharya A (2020) Comparison of energy absorption characteristics of PCM-metal foam systems with different pore size distributions. J Energy Storage 28:101190. https://doi.org/10.1016/j.est.2019.101190
Guo J, Liu Z, Du Z, Yu J, Yang X, Yan J (2021) Effect of fin-metal foam structure on thermal energy storage: an experimental study. Renew Energy 172:57–70. https://doi.org/10.1016/j.renene.2021.03.018
Sevilla P, Aparicio C, Planell JA, Gil FJ (2007) Comparison of the mechanical properties between tantalum and nickel-titanium foams implant materials for bone ingrowth applications. J Alloys Compd 439(1-2):67–73. https://doi.org/10.1016/j.jallcom.2006.08.069
Sun G, Wang Z, Yu H, Gong Z, Li Q (2019) Experimental and numerical investigation into the crashworthiness of metal-foam-composite hybrid structures. Compos Struct 209:535–547. https://doi.org/10.1016/j.compstruct.2018.10.051
Ji K, Zhao H, Huang Z, Dai Z (2014) Performance of open-cell foam of Cu-Ni alloy integrated with graphene as a shield against electromagnetic interference. Mater Lett 122:244–247. https://doi.org/10.1016/j.matlet.2014.02.025
Queheillalt DT, Katsumura Y, Wadley HNG (2004) Synthesis of stochastic open cell Ni-based foams. Scr Mater 50(3):313–317. https://doi.org/10.1016/j.scriptamat.2003.10.016
Aramesh M, Shabani B (2022) Metal foam-phase change material composites for thermal energy storage: a review of performance parameters. Renewable Sustainable Energy Rev 155:111919. https://doi.org/10.1016/j.rser.2021.111919
Li H, Chen S, He M, Jin J, Zhu K, Peng F, Gao F (2022) Self-supported V-doped NiO electrocatalyst achieving a high ammonia yield of 30.55 μg h−1 cm−2 under ambient conditions. New J Chem. https://doi.org/10.1039/d2nj02867k
Changdar A, Chakraborty SS (2021) Laser processing of metal foam - a review. J Manuf Process 61:208–225. https://doi.org/10.1016/j.jmapro.2020.10.012
Yu CF, Lin LY (2016) Effect of the bimetal ratio on the growth of nickel cobalt sulfide on the Ni foam for the battery-like electrode. J Colloid Interface Sci 482:1–7. https://doi.org/10.1016/j.jcis.2016.07.059
Bidault F, Brett DJL, Middleton PH, Abson N, Brandon NP (2009) A new application for nickel foam in alkaline fuel cells. Int J Hydrog Energy 34(16):6799–6808. https://doi.org/10.1016/j.ijhydene.2009.06.035
Zhou ZQ, Lin GW, Zhang JL, Ge JS, Shen JR (1999) Degradation behavior of foamed nickel positive electrodes of Ni-MH batteries. J Alloys Compd 293-295:795–798. https://doi.org/10.1016/s0925-8388(99)00465-x
Longerich S, Piontek D, Ohse P, Harms A, Dilthey U, Angel S, Bleck W (2007) Joining strategies for open porous metallic foams on iron and nickel base materials. Adv Eng Mater 9(8):670–678. https://doi.org/10.1002/adem.200700114
Banhart J (2001) Manufacture, characterisation and application of cellular metals and metal foams. Prog Mater Sci 46(6):559–632. https://doi.org/10.12691/ajme-6-3-5
Wang L, Xie Y, Wei C, Lu X, Li X, Song Y (2015) Hierarchical NiO superstructures/foam Ni electrode derived from Ni metal-organic framework flakes on foam Ni for glucose sensing. Electrochim Acta 174:846–852. https://doi.org/10.1016/j.electacta.2015.06.086
Jiang T, Zhang S, Qiu X, Zhu W, Chen L (2007) Preparation and characterization of silicon-based three-dimensional cellular anode for lithium ion battery. Electrochem Commun 9(5):930–934. https://doi.org/10.1016/j.elecom.2006.11.031
Fan X, Zhuang Q, Jiang H, Huang L, Dong Q, Sun S (2007) Three-dimensional porous Cu6Sn5 alloy anodes for lithium-ion batteries. Acta Phys-Chimica Sin 23(7):973–977. https://doi.org/10.1016/s1872-1508(07)60051-5
Chen C, Wu J, Li H (2021) Optimization design of cylindrical rivet in flat bottom riveting. Thin-Walled Struct 168:108292. https://doi.org/10.1016/j.tws.2021.108292
Li H, Yi R, Chen C (2022) Microstructure and mechanical performance of dissimilar material joints of 2024Al and SiO2 glass by ultrasonic assisted soldering with Cu interlayer. J Mater Res Technol 18:3227–3239. https://doi.org/10.1016/j.jmrt.2022.03.155
Peng H, Chen C, Ren X, Ran X, Gao X (2021) Research on the material flow and joining performance of two-strokes flattening clinched joint. Thin-Walled Struct 169:108289. https://doi.org/10.1016/j.tws.2021.108289
Qin D-L, Chen C (2022) Failure behavior and mechanical properties of novel dieless clinched joints with different sheet thickness ratios. J Cent South Univ 29(9):3077–3087. https://doi.org/10.1007/s11771-022-5120-8
Ran X, Chen C, Zhang H, Ouyang Y (2021) Investigation of the clinching process with rectangle punch. Thin-Walled Struct 166:108034. https://doi.org/10.1016/j.tws.2021.108034
Shi C, Li H, Chen C, Ouyang Y, Qin D (2022) Experimental investigation of the flat clinch-rivet process. Thin-Walled Struct 171:108612. https://doi.org/10.1016/j.tws.2021.108612
Zhang X, Chen C (2022) Experimental investigation of joining aluminum alloy sheets by stepped mechanical clinching. J Mater Res Technol 19:566–577. https://doi.org/10.1016/j.jmrt.2022.05.046
Feng M-N, Xie Y, Zhao C-F, Luo Z (2018) Microstructure and mechanical performance of ultrasonic spot welded open-cell Cu foam/Al joint. J Manuf Process 33:86–95. https://doi.org/10.1016/j.jmapro.2018.04.022
Xie Y, Feng M, Cai Y, Luo Z (2017) Ultrasonic spot welding of nickel foam sheet and aluminum solid sheet. Adv Eng Mater 19(8). https://doi.org/10.1002/adem.201700094
Crupi V, Montanini R (2007) Aluminium foam sandwiches collapse modes under static and dynamic three-point bending. Int J Impact Eng 34(3):509–521. https://doi.org/10.1016/j.ijimpeng.2005.10.001
Biffi CA, Colombo D, Tuissi A (2014) Laser beam welding of CuZn open-cell foams. Opt Lasers Eng 62:112–118. https://doi.org/10.1016/j.optlaseng.2014.05.005
Biffi CA, Casati R, Previtali B, Tuissi A (2016) Microstructure and mechanical properties of laser welded beads realized for joining CuZn open cellular foams. Mater Lett 181:132–135. https://doi.org/10.1016/j.matlet.2016.05.161
Biffi CA, Previtali B, Tuissi A (2017) Microstructure and calorimetric behavior of laser welded open cell foams in CuZnAl shape memory alloy. Funct Mater Lett 09(06). https://doi.org/10.1142/s1793604716420078
Oliveira JP, Panton B, Zeng Z, Omori T, Zhou Y, Miranda RM, Braz Fernandes FM (2016) Laser welded superelastic Cu-Al-Mn shape memory alloy wires. Mater Des 90:122–128. https://doi.org/10.1016/j.matdes.2015.10.125
Haferkamp H, Bunte J, Herzog D, Ostendorf A (2013) Laser based welding of cellular aluminium. Sci Technol Weld Join 9(1):65–71. https://doi.org/10.1179/136217104225017170
Tan JC, Westgate SA, Clyne TW (2013) Resistance welding of thin stainless steel sandwich sheets with fibrous metallic cores: experimental and numerical studies. Sci Technol Weld Join 12(6):490–504. https://doi.org/10.1179/174329307x213666
Jarvis T, Voice W, Goodall R (2011) The bonding of nickel foam to Ti-6Al-4V using Ti-Cu-Ni braze alloy. Mater Sci Eng: A 528(6):2592–2601. https://doi.org/10.1016/j.msea.2010.11.077
Kitazono K, Kitajima A, Sato E, Matsushita J, Kuribayashi K (2002) Solid-state diffusion bonding of closed-cell aluminum foams. Mater Sci Eng: A 327(2):128–132. https://doi.org/10.1016/S0921-5093(01)01766-X
Liu C, Zhu Z, Han F, Banhart J (1998) Internal friction of foamed aluminium in the range of acoustic frequencies. J Mater Sci 33(7):1769–1775
Born C, Kuckert H, Wagner G, Eifler D (2003) Ultrasonic torsion welding of sheet metals to cellular metallic materials. Adv Eng Mater 5(11):779–786. https://doi.org/10.1002/adem.200310102
Born C, Wagner G, Eifler D (2006) Ultrasonically welded aluminium foams/sheet metal - joints. Adv Eng Mater 8(9):816–820. https://doi.org/10.1002/adem.200600083
Ni ZL, Yang JJ, Hao YX, Chen LF, Li S, Wang XX, Ye FX (2020) Ultrasonic spot welding of aluminum to copper: a review. Int J Adv Manuf Technol 107(1-2):585–606. https://doi.org/10.1007/s00170-020-04997-5
Nowacki J, Moraniec K (2015) Welding of metallic AlSi foams and AlSi-SiC composite foams. Arch Civ Mech Eng 15(4):940–950. https://doi.org/10.1016/j.acme.2015.02.007
Böllinghaus T, Von Hagen H, Bleck W, Werden Aluminium H (2000) Laserstrahlschweißen von schäumbarem Aluminiumhalbzeug. UTF. Science 11:23–26
Peng P, Wang K, Wang W, Huang L, Qiao K, Che Q, Xi X, Zhang B, Cai J (2019) High-performance aluminium foam sandwich prepared through friction stir welding. Mater Lett 236:295–298. https://doi.org/10.1016/j.matlet.2018.10.125
Hangai Y, Kamada H, Utsunomiya T, Kitahara S, Kuwazuru O, Yoshikawa N (2014) Aluminum alloy foam core sandwich panels fabricated from die casting aluminum alloy by friction stir welding route. J Mater Process Technol 214(9):1928–1934. https://doi.org/10.1016/j.jmatprotec.2014.04.010
Shih J-S, Tzeng Y-F, Yang J-B (2011) Principal component analysis for multiple quality characteristics optimization of metal inert gas welding aluminum foam plate. Mater Des 32(3):1253–1261. https://doi.org/10.1016/j.matdes.2010.10.001
Zuo X, Zhang W, Chen Y, Oliveira JP, Zeng Z, Li Y, Luo Z, Ao S (2022) Wire-based directed energy deposition of NiTiTa shape memory alloys: microstructure, phase transformation, electrochemistry, X-ray visibility and mechanical properties. Addit Manuf 59. https://doi.org/10.1016/j.addma.2022.103115
Hangai Y, Utsunomiya T (2008) Fabrication of porous aluminum by friction stir processing. Metall Mater Trans A 40(2):275–277. https://doi.org/10.1007/s11661-008-9733-9
Ashby MF, Evans T, Fleck NA, Hutchinson J, Wadley H, Gibson L (2000) Metal foams: a design guide. Elsevier 16(5):13-16.
Banhart J (2013) Light-metal foams-history of innovation and technological challenges. Adv Eng Mater 15(3):82–111. https://doi.org/10.1002/adem.201200217
Sathiskumar R, Murugan N, Dinaharan I, Vijay S (2013) Role of friction stir processing parameters on microstructure and microhardness of boron carbide particulate reinforced copper surface composites. Sadhana 38(6):1433–1450. https://doi.org/10.1007/s12046-013-0184-7
Nisa SU, Pandey S, Pandey PM (2020) Formation and characterization of 6063 aluminum metal foam using friction stir processing route. Mater Today: Proc 26:3223–3227. https://doi.org/10.1016/j.matpr.2020.02.903
Hangai Y, Takada K, Fujii H, Aoki Y, Utsunomiya T (2019) Foaming behavior of blowing- and stabilization-agent-free aluminum foam precursor during spot friction stir welding. J Mater Process Technol 265:185–190. https://doi.org/10.1016/j.jmatprotec.2018.10.013
Sharma VM, Pal SK, Racherla V (2021) Fabrication of copper foam using friction processing. Manuf Lett 29:61–64. https://doi.org/10.1016/j.mfglet.2021.06.004
Sanga B, Wattal R, Nagesh D (2018) Mechanism of joint formation and characteristics of interface in ultrasonic welding: literature review. Period Eng Nat Sci 6(1):107–119. https://doi.org/10.21533/pen.v6i1.158
Tao W, Su X, Wang H, Zhang Z, Li H, Chen J (2019) Influence mechanism of welding time and energy director to the thermoplastic composite joints by ultrasonic welding. J Manuf Process 37:196–202. https://doi.org/10.1016/j.jmapro.2018.11.002
Daniels H (1965) Ultrasonic welding. Ultrasonics 3(4):190–196. https://doi.org/10.1016/0041-624X(65)90169-1
Zhang G-P, Li J-C, Liu Z-X, Wang P-C (2020) Application of ultrasonic welding to repair adhesively bonded short carbon fiber reinforced Nylon 6 composites. Int J Adhes Adhes 100:102603. https://doi.org/10.1016/j.ijadhadh.2020.102603
Kumar S, Wu C, Padhy G, Ding W (2017) Application of ultrasonic vibrations in welding and metal processing: a status review. J Manuf Process 26:295–322. https://doi.org/10.1016/j.jmapro.2017.02.027
Matheny M, Graff K (2015) Ultrasonic welding of metals in power ultrasonics, vol 259-293. Elsevier. https://doi.org/10.1016/B978-1-78242-028-6.00011-9
Yang Y, Ram GJ, Stucker B (2009) Bond formation and fiber embedment during ultrasonic consolidation. J Mater Process Technol 209(10):4915–4924. https://doi.org/10.1016/j.jmatprotec.2009.01.014
Zhao Y, Li D, Zhang Y (2013) Effect of welding energy on interface zone of Al-Cu ultrasonic welded joint. Sci Technol Weld Join 18(4):354–360. https://doi.org/10.1179/1362171813Y.0000000114
Yang J, Cao B, He X, Luo H (2014) Microstructure evolution and mechanical properties of Cu-Al joints by ultrasonic welding. Sci Technol Weld Join 19(6):500–504. https://doi.org/10.1179/1362171814Y.0000000218
Klocke F, Castell-Codesal A, Donst D (2005) Process characteristics of laser brazing aluminium alloys. Adv Mat Res 36:135–142. https://doi.org/10.4028/www.scientific.net/AMR.6-8.135
Zhou L, Zhu S, Zheng W, Li T, Wu L, Zhang Z, Lei Z (2020) Constant current induction brazing process optimization of AgCdO15-Cu electrical contact. J Manuf Process 51:122–129. https://doi.org/10.1016/j.jmapro.2020.01.022
Takemoto T, Okamoto I (1988) Intermetallic compounds formed during brazing of titanium with aluminium filler metals. J Mater Sci 23(4):1301–1308. https://doi.org/10.2464/jilm.36.627
Li Y, Chen C, Yi R, Ouyang Y (2020) Review: Special brazing and soldering. J Manuf Process 60:608–635. https://doi.org/10.1016/j.jmapro.2020.10.049
He R, Hu P, Zhang X, Han W, Wei C, Hou Y (2013) Preparation of high solid loading, low viscosity ZrB2-SiC aqueous suspensions using PEI as dispersant. Ceram Int 39(3):2267–2274. https://doi.org/10.1016/j.ceramint.2012.08.073
Hu P, Wang Z (2010) Flexural strength and fracture behavior of ZrB2-SiC ultra-high temperature ceramic composites at 1800° C. J Eur Ceram Soc 30(4):1021–1026. https://doi.org/10.1016/j.jeurceramsoc.2009.09.029
Cui B, Huang JH, Xiong JH, Zhang H (2013) Reaction-composite brazing of carbon fiber reinforced SiC composite and TC4 alloy using Ag-Cu-Ti-(Ti+ C) mixed powder. Mater Sci Eng: A 562:203–210. https://doi.org/10.1016/j.msea.2012.11.031
Feng J, Liu D, Zhang L, Lin X, He P (2010) Effects of processing parameters on microstructure and mechanical behavior of SiO2/Ti-6Al-4V joint brazed with AgCu/Ni interlayer. Mater Sci Eng: A 527(6):1522–1528. https://doi.org/10.1016/j.msea.2009.10.050
Kim T, Park SW (2000) Effects of interface and residual stress on mechanical properties of ceramic/metal system. Key Eng Mater 183:1279–1284. https://doi.org/10.4028/www.scientific.net/KEM.183-187.1279
Wang X, Cheng L, Fan S, Zhang L (2012) Microstructure and mechanical properties of the GH783/2.5 DC/SiC joints brazed with Cu-Ti+ Mo composite filler. Mater Des 1980-2015 36:499–504. https://doi.org/10.1016/j.matdes.2011.11.058
Zaharinie T, Moshwan R, Yusof F, Hamdi M, Ariga T (2014) Vacuum brazing of sapphire with Inconel 600 using Cu/Ni porous composite interlayer for gas pressure sensor application. Mater Des 1980-2015(54):375–381. https://doi.org/10.1016/j.matdes.2013.08.046
Wang G, Cai Y, Wang W, Gui K, Zhu D, Tan C, Cao W (2019) Brazing ZrB2-SiC ceramics to Inconel 600 alloy without and with Cu foam. J Manuf Process 41:29–35. https://doi.org/10.1016/j.jmapro.2019.03.023
Sun R, Zhu Y, Guo W, Peng P, Li L, Zhang Y, Fu J, Li F, Zhang L (2018) Microstructural evolution and thermal stress relaxation of Al2O3/Cr18Ni9Ti brazed joints with nickel foam. Vacuum 148:18–26. https://doi.org/10.1016/j.vacuum.2017.10.030
Li M, Shi K, Zhu D, Dong D, Liu L, Wang X (2021) Microstructure and mechanical properties of Si3N4 ceramic and (TiB + Y2O3)/Ti matrix composite joints brazed with AgCu/Cu foam/AgCu multilayered filler. J Manuf Process 66:220–227. https://doi.org/10.1016/j.jmapro.2021.04.025
Funding
This work was supported by the National Natural Science Foundation of China (Grant No. 51905358) and Natural Science Foundation of Hebei Province (Grant Nos. E2020210077 and E2020210095).
Author information
Authors and Affiliations
Contributions
The inception and design of this study were a collective effort among all authors. The initial conception of the thesis was carried out by Mengnan Feng and Peng Wang, who further reviewed and revised the first draft. The primary draft of the manuscript was meticulously crafted by Liang Ren. The literature collection was carried out by Ziyao Wang, Dequan Meng, and Shuo Wang, who further provided insightful comments on earlier versions of the manuscript. Finally, all authors meticulously reviewed and approved the final manuscript prior to its submission.
Corresponding authors
Ethics declarations
Ethics approval
Not applicable.
Consent to participate
Not applicable.
Consent for publication
Not applicable.
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Feng, M., Ren, L., Wang, Z. et al. Recent research progress of foam metals welding: a review. Int J Adv Manuf Technol 127, 3135–3156 (2023). https://doi.org/10.1007/s00170-023-11709-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-11709-2