Production of homogeneous aluminum foams by mechanical alloying

In a joint project between the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) and the Chair of Composite Materials and Material Compounds (PVW) at Chemnitz University of Technology, the powder metallurgical production and the mechanical behavior of aluminum foams are being investigated. The main goal is the developing of powder-metallurgical aluminum foams with an even pore structure and a lower scattering of the foam properties. This should contribute to a better predictability of the foam properties and the reliable use of metal foams as a structural material in lightweight constructions. The manufacturing route consists of the steps: high-energy ball milling (HEBM), extrusion and foaming. Building on many years of experience in the field of high-energy ball milling at PVW, a blowing agent component (TiH₂) is homogeneously dispersed into ductile aluminum powder particles by means of HEBM process, and the resulted preform is optimized for the subsequent process steps. Subsequently, the novel preform powder is further processed at the IWU through extrusion into semi-finished products, which are then subjected to a foaming process. Based on an extensive know-how for the foaming of aluminum, the IWU team investigates the consolidation and foaming behavior of the Al/TiH₂ preform powder produced by HEBM.

The research project is coordinated by Dr. Steve Siebeck from Fraunhofer IWU and supported by several process-related companies in a project-accompanying committee. The Kickoff-Meeting took place on July 15, 2020 at IWU Chemnitz with the participation of representatives of the two research centers (IWU and PVW) and the project accompanying committee.

First results of preliminary work have been already published and can be called up under the following link.

The project entitled:" Manufacturing of powder metallurgical aluminum foams with an optimized microstructure through mechanical alloying"" is funded by Stifterverband Metalle e. V. as a member of AiF until October 2022.

Further information can be obtained from Dr. Maik Trautmann and Prof. Dr. Guntram Wagner.