TY - JOUR

T1 - Development of EN AW-6082 Metal Foams and Stochastic Foam Modeling for the Individualization of Extruded Profiles

AU - Schäfke, Florian Patrick

AU - Timmann, Frederic

AU - Klose, Christian

AU - Hürkamp, André

AU - Dröder, Klaus

AU - Maier, Hans Jürgen

N1 - Acknowledgments: Financial support by Deutsche Forschungsgemeinschaft (project ID 442092412) is gratefully acknowledged. Funding: Open Access funding enabled and organized by Projekt DEAL.

PY - 2024/3

Y1 - 2024/3

N2 - Lightweight design and hybrid components enable innovative and new component concepts, especially when combining structurally reliable metal components with individualized polymer components. In this research, a process for additive manufacturing polymers on the surface of extruded aluminum profiles is examined. The extrusion process is adapted to produce foamable aluminum profiles, which can be utilized to enable a form fit between the two materials and ensures sufficient bond strength. For this purpose, a novel aluminum block material based on the standard wrought alloy EN AW-6082 was developed. It consists of a solid EN AW-6082 core and powder metallurgically produced outer layer, which allows local foaming of the aluminum profile surface. The main objective of this study was to optimize the bond strength of the hybrid aluminum-polymer components. The methods employed include fabricating aluminum test specimens, performing mechanical tests, x-ray microscopy to analyze the pore structure and evaluating the 3D pore distribution and the wall thickness. Virtual foam models were created to numerically investigate suitable pore sizes and foam geometries for form-fit with the polymer. The porosity achieved as a function of the processing of the components are discussed and a comparison is made between the real and virtual pore structures.

AB - Lightweight design and hybrid components enable innovative and new component concepts, especially when combining structurally reliable metal components with individualized polymer components. In this research, a process for additive manufacturing polymers on the surface of extruded aluminum profiles is examined. The extrusion process is adapted to produce foamable aluminum profiles, which can be utilized to enable a form fit between the two materials and ensures sufficient bond strength. For this purpose, a novel aluminum block material based on the standard wrought alloy EN AW-6082 was developed. It consists of a solid EN AW-6082 core and powder metallurgically produced outer layer, which allows local foaming of the aluminum profile surface. The main objective of this study was to optimize the bond strength of the hybrid aluminum-polymer components. The methods employed include fabricating aluminum test specimens, performing mechanical tests, x-ray microscopy to analyze the pore structure and evaluating the 3D pore distribution and the wall thickness. Virtual foam models were created to numerically investigate suitable pore sizes and foam geometries for form-fit with the polymer. The porosity achieved as a function of the processing of the components are discussed and a comparison is made between the real and virtual pore structures.

KW - additive manufacturing

KW - aluminum foam

KW - compression test

KW - virtual foam model

KW - x-ray microscopy

UR - http://www.scopus.com/inward/record.url?scp=85180213180&partnerID=8YFLogxK

U2 - 10.1007/s11665-023-09031-9

DO - 10.1007/s11665-023-09031-9

M3 - Article

AN - SCOPUS:85180213180

VL - 33

SP - 2653

EP - 2669

JO - Journal of Materials Engineering and Performance

JF - Journal of Materials Engineering and Performance

SN - 1059-9495

IS - 6

ER -