New foaming agents for aluminum foams

New foaming agents for aluminum foams

Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.co...

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Materials Today: Proceedings xxx (xxxx) xxx

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New foaming agents for aluminum foams Sergei Ganin a,⇑, Valerii Tsemenko a, Iskandar Masgutov a, Vesselin Michailov b, Alexey Eremin c a

Peter the Great St. Petersburg Polytechnic University, Polytechnicheskaya, 29, St. Petersburg 195251, Russian Federation Brandenburg University of Technology Cottbus – Senftenberg, Platz der Deutschen Einheit 1, Cottbus 03046, Germany c Institute of Macromolecular Compounds RAS, Bolshoy pr. 31, 199004, St. Petersburg, Russian Federation b

a r t i c l e

i n f o

Article history: Received 24 December 2019 Accepted 30 December 2019 Available online xxxx Keywords: Aluminum foams Heat treatment Hot extrusion Foaming agents Microstructure

a b s t r a c t This article provides alternatives to titanium hydride foaming compositions for the production of aluminum foam. Using methods of hot plastic deformation, preforms containing various blowing agents were obtained. In the laboratory furnace, the obtained samples were foamed. After that, samples were made and an analysis of the structure of the samples was carried out. Ó 2020 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the scientific committee of the Materials Science: Composites, Alloys and Materials Chemistry. All rights reserved.

1. Introduction Metal foams are a promising material for creating lightweight and durable structures. Currently, such materials can be in demand in construction, engineering, engineering, automotive, aviation and space industries However, their use is limited due to complexity of their creation and production. To increase strength such materials are often used as part of various multilayer composites. To obtain higher strength and lighter materials than ordinary metal foams, layered composite materials colloquially referred to as ‘‘sandwiches” have been developed. These have a three-layer structure of foam metal as the core and dense metal as the outer layer. The properties of sandwiches are a superposition of the properties of sheet metal and metal foams. To illustrate, obtaining three-layer aluminum sandwich panels using metal forming methods is exceedingly difficult, but they can be obtained lightly by powder metallurgy methods. In this case, the main stages of the process are obtaining a powder mixture for foaming, compacting it, joining layers of a dense metal and a workpiece from a powder mixture, pressure treatment and foaming during the final heat treatment. [1–5] A key technological step is the selection of a porophore blowing agent since the properties of the final product depend entirely on the properties of the resulting foam. Further important factors is ⇑ Corresponding author.

setting the foaming temperature and temperature application time as pore size, pore properties, dispersion and volume of the obtained sample are curled from it, well as from the time the process takes and the solidification time. Titanium hydride, a non-stoichiometric compound with TiH stoichiometry (1.8–1.99), has seen almost exclusive use in foaming agent and aluminium foam applications. It is difficult to obtain resulting in high costs, yet repeated attempts to replace it with cheaper and simpler compounds have met failure. [6–8] The aim of this study was to investigate the possibility of using alternative porophores for the production of foams.

2. Methods The following materials were attempted as foaming agents: For the study, foaming compositions identical to the porophores used for foaming glass were selected:  Mix № 1: SiO2nH2O-NaHCO3-CaCO3;  Mix № 2: SiO2nH2O-Na2CO3-CaCO3;  Mix № 3: SiO2nH2O-Na2CO3-CaCO3-NaCl. Also, for comparison, standard porophores were taken:  Hydromagnesite («magnesia»): mMgCO3∙Mg(OH)2nH2O;  Titanium hydride: TiH2.

E-mail address: [email protected] (S. Ganin). https://doi.org/10.1016/j.matpr.2019.12.402 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the scientific committee of the Materials Science: Composites, Alloys and Materials Chemistry. All rights reserved.

Please cite this article as: S. Ganin, V. Tsemenko, I. Masgutov et al., New foaming agents for aluminum foams, Materials Today: Proceedings, https://doi. org/10.1016/j.matpr.2019.12.402

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Silicic acid SiO2nH2O was dried in air at 80° C until a constant mass. Average carbonates of sodium, calcium and sodium chloride were dried in an oven at 105° C. Sodium bicarbonate (baking soda) and hydromagnesite were used without preliminary preparation. All components of the porophores were weighed on laboratory scales up to hundredths of a gram. AKD-12 aluminum alloy powder was used as the base metal. This powder refers to alloyed powders. It consists of 86.5% aluminum, 13% silicon and 0.5% iron. The size of the powder fraction was 140–315 lm.

Fig. 2. Samples after the extrusion process.

2.1. Powder mixture homogenization for prototypes The next step is the gravity mixer «drunk barrel» or «Cone blender» received the final powder mixture for foaming. The base material - aluminum alloy AKD-12 and the previously obtained porophores were mixed in a ratio of 99% (69.3 g) to 1% (0.7 g) with the addition of glass balls of 30% of the mass: [9–11]  Mixing time 30 min.  Mixing speed 80 rpm. This step is necessary to obtain a uniform distribution of the blowing agent in the powder mixture. Otherwise, clusters of porophore will form in separate places. This will entail excessive gas evolution, which means an inhomogeneous structure with different bubble sizes.

Fig. 3. Samples after heating at a temperature of 650 °C.

2.2. Powder compaction The homogenization was followed by the process of pressing the powder mixture. Compaction was carried out on a PSU-50

Fig. 4. Samples after heating at a temperature of 700 °C.

hydraulic press with a force of 7 tons in a 25 mm matrix (1.43 t/ cm2). The resulting blanks in the form of ‘‘tablets” were placed in aluminum cylinders which served as the outer layer in the resulting sandwich composite [12–16]. 2.3. Extrusion process At the PSU-125 laboratory hydraulic press the powder mixture blanks were extruded for foaming in aluminum cylinders (Fig. 1) [17–19]. The extruder with the placed billet was heated to a temperature of 420 °C and held for 20 min, after which it was extruded at a load of 30 tons. The resulting rods with a diameter of 10 mm were cut into samples (Fig. 2), 3 pieces each for further heat treatment. 2.4. Foaming process

Fig. 1. The extrusion process.

The foaming stage was carried out in a laboratory electric furnace PL 20 / 12.5 at three temperatures: 540, 650 and 700 °C. Temperatures were chosen empirically through calculating the dependence of the volume change on temperature. The heating time is 5 min. It is optimal for all temperature conditions.

Please cite this article as: S. Ganin, V. Tsemenko, I. Masgutov et al., New foaming agents for aluminum foams, Materials Today: Proceedings, https://doi. org/10.1016/j.matpr.2019.12.402

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Fig. 5. Longitudinal section of samples.

3. Results and discussion After treating the samples at a temperature of 540C their appearance did not change as this heat level corresponds to the beginning of the foaming process. At this stage a structural change occurs, making the beginning of bubble nucleation. When the temperature was increased by 110 °C external changes began to occur (Fig. 3). As illustrated by the photograph of the samples, after heat treatment at a temperature of 650 °C new porophores suffer a marginal increase in volume over standard TiH2 and magnesia blowing agents. Fig. 4 shows the samples after heat treatment at 700 °C. Samples with new blowing agents are not inferior in volume to samples containing titanium hydride and magnesia as porophores. Fig. 5 shows photographs of the samples after grinding the surface. It can be noted that in the sample where magnesia was used as a porophore pores of uneven size were formed [20].

4. Conclusions In conclusion we propose new compositions of blowing agents based on glass transition processes that emit a significant amount of CO2 in the temperature range of AKD-12 alloy melting. Experimentally, an optimal temperature of 700 °C was established for foaming aluminum based on the proposed porophores. The foam aluminum obtained using these porophores has a homogeneous structure, spherical pores are not large in size, as a consequence

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Please cite this article as: S. Ganin, V. Tsemenko, I. Masgutov et al., New foaming agents for aluminum foams, Materials Today: Proceedings, https://doi. org/10.1016/j.matpr.2019.12.402