Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

High strength cellular aluminium foam for the automotive industry

11.06.2014

Aluminum foam is used for applications that requires high level of energy and sound absorption characteristics. UiTM researchers have developed an innovative process to make high strength cellular aluminium foam with help from some salt.

Aluminium foam exhibits unique properties when compared to its dense form, particularly its lightweight characteristics. Generally, the foam can be divided into two categories; closed cell and open cell, both have different characteristics and applications.

The features of the closed cell are, the pores structure is isolated and they are not connected to each other. This type of aluminium foam is suitable for application that requires high level of energy and sound absorption characteristics. It has been used widely in many structural parts, particularly in areas exposed to high damping capacity, for example in the automotive front bumper component.

Meanwhile, the open cell, owing to greater level of connectivity of the pores, the structure has been accepted and used in thermal management applications. One such promising application is as a heat exchanger, particularly as a cooling medium to transfer heat, due to the development of its porous structure, which provides greater surface area, thus, enabling improved heat transfer efficiency. Producing a combined structure of open and closed cell in one volume component appears to be a difficult process due to the different processing techniques involved and their individual limitations.

Therefore, in this study, an innovative processing route for high strength cellular aluminium foam (CAF) by integrating porous and dense structures is presented. The CAF is well known as a light-weight product exhibiting high level of inter-connected porosity which is very useful as a thermal management application, particularly as a heat transfer or cooling medium. However, the level of strength for the CAF is not really promising when it is subjected to high impact; thus, limit its potential application, particularly in the automotive industry.

Subsequently, an alternative route by integrating dense and porous structure has been investigated. The solid aluminium at the centre acts as a pillar providing excellent strength for the surrounding foam structure. The product has demonstrated functionally graded properties which is possible for applications that require both properties of heat transfer and high strength.

The product was fabricated using infiltration of NaCl space holder combined with central solid aluminium foam. It is well known that NaCl has a greater melting point than that of aluminium. Therefore, when aluminium melts, the liquid fills the interstitial spaces between the NaCl grain. Prior to melting, the NaCl is sieved according to the desired porous structure.

The materials (NaCl, central aluminium core and dense Aluminium ingot) are placed in the cylindrical steel mould and heated at temperature range between 670 and 700oC. The NaCl is placed at the bottom mould with aluminium central pillar and bulk Aluminium placed at the top of NaCl so that after the aluminium turns into liquid, it penetrates along the interstitial spaces between NaCl. Upon solidification, the part is removed from the mould and further machining is carried out to remove surface roughness caused by the solidification process. The part is then leached in an ultrasonic water bath in order to remove the NaCl completely.

The final product is the cellular aluminium foam exhibiting excellent interconnected pores structure with dense central pillar. The central solid pillar provides extra strength for the surrounded foam structure. The foams structure produced was examined for its density, porosity and strength by compression test. Thermal conductivity was also carried out to investigate the effect of space holder size and the NaCl fractions on the final properties.

MUHAMMAD HUSSAIN BIN ISMAIL
Faculty of Mechanical Engineering
University Teknologi MARA, Malaysia
hussain305@salam.uitm.edu.my 

Funding information

University Teknologi MARA

Darmarajah Nadarajah | Research SEA News
Further information:
http://www.uitm.edu.my
http://www.researchsea.com

Further reports about: UiTM characteristics dense foam heat pores porous processing structure techniques

More articles from Automotive Engineering:

nachricht 3D scans for the automotive industry
16.01.2017 | Julius-Maximilians-Universität Würzburg

nachricht Improvement of the operating range and increasing of the reliability of integrated circuits
09.11.2016 | Technologie Lizenz-Büro (TLB) der Baden-Württembergischen Hochschulen GmbH

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Breakthrough with a chain of gold atoms

In the field of nanoscience, an international team of physicists with participants from Konstanz has achieved a breakthrough in understanding heat transport

In the field of nanoscience, an international team of physicists with participants from Konstanz has achieved a breakthrough in understanding heat transport

Im Focus: DNA repair: a new letter in the cell alphabet

Results reveal how discoveries may be hidden in scientific “blind spots”

Cells need to repair damaged DNA in our genes to prevent the development of cancer and other diseases. Our cells therefore activate and send “repair-proteins”...

Im Focus: Dresdner scientists print tomorrow’s world

The Fraunhofer IWS Dresden and Technische Universität Dresden inaugurated their jointly operated Center for Additive Manufacturing Dresden (AMCD) with a festive ceremony on February 7, 2017. Scientists from various disciplines perform research on materials, additive manufacturing processes and innovative technologies, which build up components in a layer by layer process. This technology opens up new horizons for component design and combinations of functions. For example during fabrication, electrical conductors and sensors are already able to be additively manufactured into components. They provide information about stress conditions of a product during operation.

The 3D-printing technology, or additive manufacturing as it is often called, has long made the step out of scientific research laboratories into industrial...

Im Focus: Mimicking nature's cellular architectures via 3-D printing

Research offers new level of control over the structure of 3-D printed materials

Nature does amazing things with limited design materials. Grass, for example, can support its own weight, resist strong wind loads, and recover after being...

Im Focus: Three Magnetic States for Each Hole

Nanometer-scale magnetic perforated grids could create new possibilities for computing. Together with international colleagues, scientists from the Helmholtz Zentrum Dresden-Rossendorf (HZDR) have shown how a cobalt grid can be reliably programmed at room temperature. In addition they discovered that for every hole ("antidot") three magnetic states can be configured. The results have been published in the journal "Scientific Reports".

Physicist Dr. Rantej Bali from the HZDR, together with scientists from Singapore and Australia, designed a special grid structure in a thin layer of cobalt in...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Booth and panel discussion – The Lindau Nobel Laureate Meetings at the AAAS 2017 Annual Meeting

13.02.2017 | Event News

Complex Loading versus Hidden Reserves

10.02.2017 | Event News

International Conference on Crystal Growth in Freiburg

09.02.2017 | Event News

 
Latest News

From rocks in Colorado, evidence of a 'chaotic solar system'

23.02.2017 | Physics and Astronomy

'Quartz' crystals at the Earth's core power its magnetic field

23.02.2017 | Earth Sciences

Antimicrobial substances identified in Komodo dragon blood

23.02.2017 | Life Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>