Low Environment Loading Process to Produce High Specific Stiffness Porous Materials Components

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Demand of Light Weight Structural Components is becoming important in the many industrial fields like automobile, machine and welfare equipments, and porous materials with lower density than 1.0 are strongly expected for industrial applications. In the present research project, the fundamental study was investigated to produce high specific stiffness porous structural component which consists of a hollow part and porous metal by combustion foaming process. The research items and results are as follows.1.Combustion foaming by total heating of precursorThe process of combustion foaming by total heating of a precursor with powder mixture was investigated for Al and Al-Ni composite foams. The effects of powder mixing ratio of precursor, amount of exothermic foaming agent, forming conditions of precursor and heating conditions on the foaming behavior and pore morphology were analyzed and cleared.2.Self-propagating foaming by partial heating of precursorThe process of self-propagating foaming by partial heating of a precursor was investigated for the same Al and Al-Ni composite foams. The effects of amount of exothermic foaming agent, pre-heating of precursor, heating position and transfer heating condition on the foaming behavior and pore morphology were analyzed and cleared.3.Producing of porous component by foaming in hollow partThe possibility to produce porous structural component by filling Al-Ni combustion foams in a hollow pipe was demonstrated. And the effects of constraint by a hollow pipe and positions of a precursor and a hollow pipe on the pore morphology of the porous component were analyzed and cleared.4. Producing of porous aluminum with exothermic foaming agent.The new process to produce porous aluminum by help of an exothermic foaming agent was investigated. The exothermic agent was added together with foaming agent, TiH_2, in aluminum powder. The foaming possibility was demonstrated and some further problems were also cleared.