Innovative Fabrication of Aluminum Alloy Foams

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It is proposed to develop better-quality aluminum foams through new processing techniques. The application of surface modified foaming agents employing electroless plating techniques will be used to improve the kinetics of gas release leading to better foaming control. In parallel, new approaches to the fabrication of modified Al-alloys foams and processing routes using mechanical alloying and reactive isothermal solidification will be studied aiming to enhance the process reproducibility and property improvement for acoustic abatement and impact absorption. The evaluation of the physical properties and characterization of the macro- and micro-structural features of the foams produced will be carried out using a variety of techniques including differential scanning calorimetry, x-ray diffraction, electron microscopy, x-ray tomography, acoustical impedance, vibration tests and microtomography analyses. The main goal is to improve the reproducibility of foam fabrication to make them more attractive and cost-effective for automotive and other applications. To achieve the objectives involves collaboration between different academic and industry partners and this will lead to substantial training of HQP. In addition, it is expected that an innovative process for the production of Al-foams will be developed that will benefit, not only the industrial partner, but also the aluminum secondary manufacturing sector which is of strategic importance in Quebec.