The reactive stabilization of Al–Zn foams using a powder metallurgy approach

Abstract

Abstract The Al–Zn binary system was chosen in order to study the possibility of generating a reactive foam system within the semi-solid region. The idea is to create foam at lower temperatures than the melting point of pure aluminum using a transient liquid phase that softens the matrix prior to bulk expansion. This minimizes crack formation, collapse, drainage and deformation generated during processing. The Al–Zn foams were fabricated via the powder metallurgy route by hot compaction and subsequently foamed using TiH 2 as a blowing agent. The investigated systems consist of low, medium and high concentrations of Zn (10 wt%, 33 wt% and 50 wt%) in an Al based matrix containing 0.8 wt% TiH 2 . High temperature in situ confocal microscopy was used to study the formation of the transient liquid phase of the compacted elemental powders. As the percentage of Zn was increased, the liquidus temperature of the melt was lowered along with an increase in the volume of transient liquid phase. This reduces the mismatch between the hydrogen release temperature of the blowing agent and the liquidus temperature of the melt, thus increasing foaming stability. Reasonable foam structures near 300 vol% expansion and fair pore distributions were achieved at low concentrations of Zn (10 wt%) only above the alloy liquidus point. The mechanical compressive strength properties of the alloyed foam systems were also assessed.