Fabrication of aluminium foams from powder by hot extrusion and foaming

In order to produce aluminium foams for light-weight and energy absorbing structures of automobiles, a method for fabricating aluminium foam from powder mixed with a foaming agent by using a mould is proposed. The method consists of four sequential processes: powder compacting, extruding, foaming and moulding. In the experiment for fabricating aluminium foam from powder, the conditions of powder extrusion and foaming by the heated die are determined from the density of the aluminium foams made without a mould. The experimental results show that the relative density of the aluminium foam made under appropriate conditions is 0.22. In moulding of aluminium foam, a stainless steel pipe is used as a mould and the cylindrical aluminium foam is produced by filling into the pipe mould. The distribution of relative density within the aluminium foam bar is in a range of 0.2–0.3 by rapid cooling of the pipe. To examine the ratio of deformation energy to weight of the pipe including the aluminium foam, a compression test using a press is carried out. The deformation energy of the pipe can be increased with aluminium foam filled by the proposed method.