Process Development for Manufacturing of Cellular Structures with Controlled Geometry and Properties

Paulo Pinto,Delfim Soares,Nuno Peixinho,Filipe Silva

doi:10.1590/1516-1439.286614

Abstract

This study presents experimental results on the behaviour of aluminium alloy metal structures and foams manufactured by lost-wax casting and using 3D printed components for internal structure definition. Results for tensile tests, metallurgical properties, surface quality and geometry tolerances were obtained and discussed. The analysis focused on development geometries, used for adjusting manufacturing parameters and prototype geometries intended for geometrical and mechanical validation. The results are indicative of the viability of the method for producing foam structures suitable for mechanical loading.

Highlights

Metallic foams are being studied as prospective materials with significant potential due to its favourable strength-density ratio which presents advantages for the development of components for the transportation industry
The foams are of open cell type and manufactured using a process of lost wax casting while recurring to 3D printing for the internal geometry definition
This study presents the development of a manufacturing process suitable for the production of aluminium metal foams with controlled geometry and properties

Summary

Introduction

Metallic foams are being studied as prospective materials with significant potential due to its favourable strength-density ratio which presents advantages for the development of components for the transportation industry. Such features as high energy absorption capacity combined with low density are interesting for use in stiffness related parts and passive safety structures[1]. High strength and excellent energy absorption in compression are favourable characteristics of metal foams that are important for the development of impact-related parts and maintaining or improving passive safety Due to this excellent performance, there is a need for continuous improvement and to refine their manufacturing processes and production[3]

Methods

Results

Conclusion