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

在汽车、机械和福利设备等许多工业领域，对轻质结构件的需求变得越来越重要，密度低于1.0的多孔材料有望用于工业应用。本研究项目对燃烧发泡法制备高比刚度多孔结构构件进行了基础性研究。研究内容和结果如下：1.前驱体全热燃烧发泡研究了Al和Al-Ni复合泡沫塑料的前驱体与粉末混合物全热燃烧发泡过程。分析和明确了前驱体粉料配比、放热发泡剂用量、前驱体成型条件和加热条件对发泡行为和孔形态的影响。2.前驱体部分加热自蔓延发泡研究了相同Al和Al-Ni复合泡沫塑料的前驱体部分加热自蔓延发泡过程。分析和明确了放热发泡剂用量、前驱体预热、加热位置和传递加热条件对发泡行为和孔形态的影响。3.中空发泡法制备多孔构件论证了在中空管内填充Al-Ni燃烧泡沫制备多孔结构构件的可能性。分析明确了中空管的约束、前驱体和中空管的位置对多孔组分孔形态的影响。利用放热式发泡剂生产多孔铝研究了放热式发泡剂生产多孔铝的新工艺。在铝粉中加入放热剂和发泡剂TiH_2。论证了发泡的可能性，并排除了进一步存在的问题。

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.