Micro-CT measurements of die-cast car parts with aluminum foam core

Abstract

Aluminum foams have low density, high energy absorption, and specific stiffness. Further strengthening of aluminum foam-based structures can be achieved by using a massive metallically bonded outer aluminum shell. Thanks to Aluinvent aluminum foaming technology and the developed casting processes, we can produce such parts with different shape, size, and controlled mechanical properties. Thus, aluminum foams and complex cast around structures with aluminum foam core are excellent candidates of cast three-dimensional (3D) shape car parts. Using micro-computed tomography (μ-CT) investigation in this study, we demonstrate that the developed aluminum foam cored high-pressure die cast around prototypes are having well controlled metallic bond and, during the casting process, the liquid aluminum penetrates in a controlled manner into the outer bubble layer of the solid aluminum foam.