Activity Integral foam moulding

Internally funded project

Project Details

Project leader:
Prof. Dr.-Ing. Carolin Körner

Contributing FAU Organisations:
Lehrstuhl für Werkstoffwissenschaften (Werkstoffkunde und Technologie der Metalle)
Technische Fakultät

Start date: 01/01/2000

Research Fields

Lightweight Materials
Lehrstuhl für Werkstoffwissenschaften (Werkstoffkunde und Technologie der Metalle)

Abstract (technical / expert description):

Integral foam molding (IFM) is an economical way to produce castings with integrated cellular structure, i.e. a solid skin and a foamed core. IFM is known for polymers since more than four decades and well established there in industrial production. Polymer integral foam parts are accepted as a material system with own properties which simplifies designs, reduces production costs and weight, and increases stiffness and overall strength. On the other hand, integral foam molding for metals is a new field of research. The development of metal based integral foam molding processes at WTM moves along analogous paths as that of polymers by transferring and adapting successful molding technologies for polymer integral foam to metals. Two molding techniques for metal integral foam are presented, a low and a high pressure process. During the low pressure integral foam molding process, the molten metal charged with blowing agent is injected into a permanent steel mold without completely filling it. In this case, the mold gets eventually filled by foam expansion. The strategy of the high pressure integral foam molding process HP-IFM is to initiate foaming by expansion of the mold cavity after it is completely filled with the mixture of the metal melt and the blowing agent.

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Hartmann, J., Blümel, C., Ernst, S., Fiegl, T., Wirth, K.-E., & Körner, C. (2014). Aluminum integral foam castings with microcellular cores by nano-functionalization. Journal of Materials Science, 49(1), 79-87.
Hartmann, J., Fiegl, T., & Körner, C. (2014). Aluminum integral foams with tailored density profile by adapted blowing agents. Applied Physics A: Materials Science and Processing, 115(2), 651-660.
Hartmann, J., Trepper, A., & Körner, C. (2011). Aluminum integral foams with near-microcellular structure. Advanced Engineering Materials, 13(11), 1050-1055.
Körner, C., & Hartmann, J. (2010). Aluminiumgussteile mit zellularem Kern. Lightweight Design, 3, 28-34.
Trepper, A. (2010). Niederdruck-Integralschaumgießen - Technologie für Aluminiumgussteile mit reduziertem Körperschall (Dissertation).
Wiehler, H. (2010). Prozessentwicklung des Hochdruckintegralschaumgießens von Aluminium (Dissertation).
Körner, C. (2008). Foam formation mechanisms in particle suspensions applied to metal foams. Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing, 495, 227-235.
Wiehler, H., Heinl, P., Körner, C., & Singer, R. (2008). High pressure integral foam moulding of aluminium. In Proceedings of the 5th International Conference on Porous Metals and Metallic Foams, MetFoam 2007 (pp. 15-18). Montreal, QC.
Wiehler, H., Körner, C., & Singer, R. (2008). High pressure integral foam moulding of aluminium - Process technology. Advanced Engineering Materials, 10(3), 171-178.
Körner, C. (2008). Integral Foam Molding of Light Metals. Springer.

Last updated on 2019-06-08 at 13:43