Details
| Original language | English |
|---|---|
| Pages (from-to) | 2653-2669 |
| Number of pages | 17 |
| Journal | Journal of Materials Engineering and Performance |
| Volume | 33 |
| Issue number | 6 |
| Early online date | 20 Dec 2023 |
| Publication status | Published - Mar 2024 |
Abstract
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.
Keywords
- additive manufacturing, aluminum foam, compression test, virtual foam model, x-ray microscopy
ASJC Scopus subject areas
- Materials Science(all)
- General Materials Science
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
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In: Journal of Materials Engineering and Performance, Vol. 33, No. 6, 03.2024, p. 2653-2669.
Research output: Contribution to journal › Article › Research › peer review
}
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 -