Mold-Filling Ability of Aluminum Alloy Melt during the Two-Step Foaming Process

doi:10.1016/j.jmst.2016.03.001

J. Mater. Sci. Technol. ›› 2016, Vol. 32 ›› Issue (6): 509-514.DOI: 10.1016/j.jmst.2016.03.001

Special Issue: 铝合金专辑

• Orginal Article • Previous Articles Next Articles

Mold-Filling Ability of Aluminum Alloy Melt during the Two-Step Foaming Process

H. Wang¹, Y.M. Zhang², B.C. Zhou¹, D.H. Yang³, Y. Wu^{1, *}, X.J. Liu¹, Z.P. Lu^{1, *}

1 State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China; 2 Department of Aviation and Military Transportation, Airforce Logistics College of PLA, Xuzhou 221000, China; 3 College of Mechanics and Materials, Hohai University, Nanjing 210098, China

Received:2015-10-30 Online:2016-06-10
Contact: Corresponding authors. Ph.D.; Tel.: +86 1062332246; Fax: +86 1062333447. (Y. Wu); (Z.P. Lu). E-mail addresses: wuyuan@ustb.edu.cn (Y. Wu); luzp@ustb.edu.cn (Z.P. Lu).
Supported by:
This work is supported by 111 Project (Grant No. B07003), the Program for Changjiang Scholars and Innovative Research Team in University (Grant No. IRT_14R05), the Fundamental Research Funds for the Central Universities (Grant No. FRF-SD-12-004A), the Special Scientific Research Fund for Doctoral Program of the Ministry of Education of the People's Republic of China (Grant No. 20110006110029), Beijing Higher Education Young Elite Teacher Project and the Research Project of the State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing (Grant No.2011-Z13).

Abstract

Abstract: For the two-step foaming method, one of the most cost-effective ways to fabricate three-dimensional shaped aluminum alloy foams with dense outer surface skin, it is crucial to describe and predict the mold-filling behavior of the shaped aluminum alloy foams with a favorable pore-distribution accurately. In this paper, a mold-filling model for semi-solid aluminum alloy foams was initially established and subsequently employed to predict the filling height, which represents the mold-filling ability of semi-solid aluminum alloy foams in a specially designed tube-like mold. Our results indicate that the proposed model can be applied to characterize the mold-filling property of aluminum alloy melts in a quantitative manner. Theoretically, our findings actually provide a guideline for mass-production of the shaped aluminum alloy foams by using the two-step foaming process.

Key words: Mould-filling, Aluminum alloy, Semi-solid metal forming

H. Wang, Y.M. Zhang, B.C. Zhou, D.H. Yang, Y. Wu, X.J. Liu, Z.P. Lu. Mold-Filling Ability of Aluminum Alloy Melt during the Two-Step Foaming Process[J]. J. Mater. Sci. Technol., 2016, 32(6): 509-514.

Figures/Tables 6

Mold for the second foaming step (a) and the pore structure of the precursor after the first foaming step (b)

Illustration of the semi-solid aluminum alloy foam filling process. (a) Sketch of rheological filling of a semi-solid aluminum foam in a round tube, and (b) the relationship between the filling force and the filling time

Relationship between the fractions of solid in the aluminum alloy melt foam and the filling time

Typical cross-sectional morphology of the aluminum foams (a) 1-4, (b) 2-3, (c) 3-3, (d) 4-4 and (e) 5-4 shown in Table 1, and the porosity of these specimens is 70.9%, 83.6%, 86.9%, 84.8% and 91.6%, respectively.

Relationship between the TiH2 content in the aluminum alloy foam and the mold-filling height

Strength comparison of the shaped aluminum alloy foams with and without dense outer skins as a function of porosity. Inset is compressive stress-strain curves of typical foams with a dense skin

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Mold-Filling Ability of Aluminum Alloy Melt during the Two-Step Foaming Process

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