Featured Research

from universities, journals, and other organizations

High strength cellular aluminium foam for the automotive industry

Date:
June 10, 2014
Source:
Universiti Teknologi MARA (UiTM)
Summary:
Aluminum foam is used for applications that requires high level of energy and sound absorption characteristics. Researchers have developed an innovative process to make high strength cellular aluminum foam with help from some salt.

Aluminum 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 aluminum 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 aluminum 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 aluminum 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 aluminum foam. It is well known that NaCl has a greater melting point than that of aluminum. Therefore, when aluminum 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 aluminum core and dense aluminum 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 aluminum central pillar and bulk aluminum placed at the top of NaCl so that after the aluminum 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 aluminum 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.


Story Source:

The above story is based on materials provided by Universiti Teknologi MARA (UiTM). Note: Materials may be edited for content and length.


Cite This Page:

Universiti Teknologi MARA (UiTM). "High strength cellular aluminium foam for the automotive industry." ScienceDaily. ScienceDaily, 10 June 2014. <www.sciencedaily.com/releases/2014/06/140610121803.htm>.
Universiti Teknologi MARA (UiTM). (2014, June 10). High strength cellular aluminium foam for the automotive industry. ScienceDaily. Retrieved July 23, 2014 from www.sciencedaily.com/releases/2014/06/140610121803.htm
Universiti Teknologi MARA (UiTM). "High strength cellular aluminium foam for the automotive industry." ScienceDaily. www.sciencedaily.com/releases/2014/06/140610121803.htm (accessed July 23, 2014).

Share This




More Matter & Energy News

Wednesday, July 23, 2014

Featured Research

from universities, journals, and other organizations


Featured Videos

from AP, Reuters, AFP, and other news services

Government Approves East Coast Oil Exploration

Government Approves East Coast Oil Exploration

AP (July 18, 2014) The Obama administration approved the use of sonic cannons to discover deposits under the ocean floor by shooting sound waves 100 times louder than a jet engine through waters shared by endangered whales and turtles. (July 18) Video provided by AP
Powered by NewsLook.com
Sunken German U-Boat Clearly Visible For First Time

Sunken German U-Boat Clearly Visible For First Time

Newsy (July 18, 2014) The wreckage of the German submarine U-166 has become clearly visible for the first time since it was discovered in 2001. Video provided by Newsy
Powered by NewsLook.com
Obama: U.S. Must Have "smartest Airports, Best Power Grid"

Obama: U.S. Must Have "smartest Airports, Best Power Grid"

Reuters - US Online Video (July 17, 2014) President Barak Obama stopped by at a lunch counter in Delaware before making remarks about boosting the nation's infrastructure. Mana Rabiee reports. Video provided by Reuters
Powered by NewsLook.com
Crude Oil Prices Bounce Back After Falling Below $100 a Barrel

Crude Oil Prices Bounce Back After Falling Below $100 a Barrel

TheStreet (July 16, 2014) Oil Futures are bouncing back after tumbling below $100 a barrel for the first time since May yesterday. Jeff Grossman is the president of BRG Brokerage and trades at the NYMEX. Grossman tells TheStreet the Middle East is always a concern for oil traders. Oil prices were pushed down in recent weeks on Libya increasing its production. Supply disruptions in Iraq fading also contributed to prices falling. News from China's economic front showing a growth for the second quarter also calmed fears on its slowdown. Jeff Grossman talks to TheStreet's Susannah Lee on this and more on the Energy Department's Energy Information Administration (EIA) report. Video provided by TheStreet
Powered by NewsLook.com

Search ScienceDaily

Number of stories in archives: 140,361

Find with keyword(s):
Enter a keyword or phrase to search ScienceDaily for related topics and research stories.

Save/Print:
Share:

Breaking News:
from the past week

In Other News

... from NewsDaily.com

Science News

Health News

Environment News

Technology News



Save/Print:
Share:

Free Subscriptions


Get the latest science news with ScienceDaily's free email newsletters, updated daily and weekly. Or view hourly updated newsfeeds in your RSS reader:

Get Social & Mobile


Keep up to date with the latest news from ScienceDaily via social networks and mobile apps:

Have Feedback?


Tell us what you think of ScienceDaily -- we welcome both positive and negative comments. Have any problems using the site? Questions?
Mobile: iPhone Android Web
Follow: Facebook Twitter Google+
Subscribe: RSS Feeds Email Newsletters
Latest Headlines Health & Medicine Mind & Brain Space & Time Matter & Energy Computers & Math Plants & Animals Earth & Climate Fossils & Ruins