Research Progress in the Preparation of Aluminum Foam Composite Structures
Abstract
:1. Introduction
2. Aluminum Foam Sandwich
2.1. Adhesive Bonding Method
2.2. Welding Method
2.2.1. Brazing
2.2.2. Diffusion Welding
2.2.3. Friction Stir Welding
2.3. Powder Metallurgy Method
2.3.1. Cold- and Hot-Pressing Powder Metallurgy Method
2.3.2. Rolling Powder Metallurgy Method
2.3.3. Jacketing Rolling Powder Metallurgy Method
2.3.4. Other Methods
2.4. Melt Foaming Method
3. Aluminum-Foam-Filled Tube
3.1. Ex Situ Filling Method
3.2. In Situ Preparation Method
3.3. Other Methods
4. Metal Grid Structure Enhanced Aluminum Foam
5. Advanced Pore Morphology Foam-Filled Composite Structure
6. Summary and Prospects
- (1)
- Most scholars have conducted additional research on the foaming mechanism and the improvement of the pore structure of traditional aluminum foam. For example, Banhart’s team conducted an in-depth study on the foaming mechanism of aluminum foam based on X-ray and tomography [117]. An’s team revealed the stabilizing agent of non-thickening foaming technology to produce aluminum foam with a uniform internal structure [118]. In AFCSs, the addition of solid plates and pipes greatly influences the pore structure during aluminum foaming. For example, the powder loss caused by the pressing and rolling processes, the influence of coated rolling on powder uniformity, and the obstruction of the metal tube wall to core layer foaming during the in situ preparation of FFTs have an impact on the pore morphology and pore size of aluminum foam. Further research is needed.
- (2)
- Although the adhesive bonding method is simple, the bonding strength between the panels and the foam core is not strong enough. Adhesive aging limits the use of AFCSs in harsh conditions such as high temperatures. The surface modification of the panels and the foam core should be researched.
- (3)
- It is difficult to control the porosity of AFCSs fabricated using the powder metallurgy method, and the size of the samples is limited by the mold and equipment used. However, the powder metallurgy method has great advantages for preparing special-shaped AFCS parts.
- (4)
- The advantages of the melt foaming method have not been fully displayed, especially in fabricating large-sized and uniform pore structure AFCSs. The flowing, expanding, and filling properties of the foamable melt during the foaming process should be studied in depth.
- (5)
- The industrial production method of AFCSs with the shape of a sandwich plate, block material, and filling tube should be focused on, and the application fields need to be expanded.
- (6)
- The key to the AFCS preparation process is to realize the effective combination between the core material and the pipe, plate, metal mesh, or other structures and ensure the structural integrity of the aluminum foam core as far as possible during the combination process. Different methods of preparing AFCSs often have distinct advantages and disadvantages.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Preparation Methods | Advantages | Disadvantages | Reference | |
---|---|---|---|---|
AFS | Adhesive bonding | Simple in process, high efficiency, and low cost. | Adhesive ages easily, corrodes easily, and does not survive high temperatures, as well as low bonding strength of prepared samples. | [17,18,21,22,26,27,28] |
Brazing | Welded AFSs present good appearance quality at brazing joints, and low cost. | Brazed joint is prone to defects, incomplete melting of the solder layer, and easy to overburn both the panels and core material. | [36,39] | |
Diffusion welding | Good bonding strength and without melting metal. | Requires a high surface quality. | [41,43,44] | |
Friction stir welding | Without introducing new materials, good bonding strength, refines grain of panel, and improves panel. | Surface of welded AFS is not smooth, and core layer is prone to large pores. | [48,51,52,53] | |
Cold- and hot-pressing powder metallurgy | AFSs prepared by this method form a tight metallurgical bonding layer with good bonding. | Preparation conditions are limited and cannot meet the requirements of industrial scale production, AFS core layer is prone to large pores, and process is complex. | [54,57,61,62] | |
Rolling powder metallurgy | Can obtain higher densification of core and present better interface bonding strength, and large-sized AFSs can be prepared. | Flow and loss of core powder, and micro-cavities can be observed in the low-density area. | [65,66,67,68,69] | |
Jacketing rolling powder metallurgy method | AFSs prepared have characteristics of good powder uniformity and high shape accuracy, density of the precursor is improved, and core powder loss is prevented. | Process requires high precision and complex preparation. | [70,71,74] | |
ARB and CAR | Can be used for fabricating large-sized AFSs. | Large pores and extremely uneven pore distribution, and smooth surface of aluminum foam plate is degraded. | [75,76,77] | |
Melt foaming | AFSs have characteristics of a short process, relatively uniform pore structures, and less limits in specimen size. | Acceptable bonding strength. | [12,79,80] | |
FFT | Ex situ filling | Thermal expansion bonding process is simple and low cost, and bonding strength is effectively improved if adhesive bonding is employed. | Surface error is large, and existence of adhesive keeps FFT from being used in high temperatures and other harsh environments. | [95,96] |
In situ preparation | Avoids secondary molding of FFTs, metallurgical bond is formed between panel and core layer, highly reproducible, and cost-effective. | Pore forming is random and uncontrollable. | [86,94,99,100,103] | |
MGS-AF | Internal method | Full play to lightweight advancement of AFCSs, and prepared MGS-AF has perfect pore structure. | Process requires two-step preparation, and process is complex. | [109,110] |
External enhancement method | Full play to lightweight advancement of AFCSs. | [2,111] | ||
APM foam-filled composite structure | Adhesive bonding | Highly repeatable, simple process, and low cost. | Adhesive ages easily, corrodes easily, and does not survive high temperatures. | [112,113,114,115,116] |
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Zhang, J.; An, Y.; Ma, H. Research Progress in the Preparation of Aluminum Foam Composite Structures. Metals 2022, 12, 2047. https://doi.org/10.3390/met12122047
Zhang J, An Y, Ma H. Research Progress in the Preparation of Aluminum Foam Composite Structures. Metals. 2022; 12(12):2047. https://doi.org/10.3390/met12122047
Chicago/Turabian StyleZhang, Junshan, Yukun An, and Haoyuan Ma. 2022. "Research Progress in the Preparation of Aluminum Foam Composite Structures" Metals 12, no. 12: 2047. https://doi.org/10.3390/met12122047