Post on 28-Jan-2021
Aluminium foam
Product information 2.2.01.08/06 GB
Powder MetallurgyPowder Extrusion Technology
· Slovak Academy of Sciences / Bratislava (Proto-
typing, Process analysis, plant engineering and
construction)
· TU Vienna / Institute of Materials Science and
Testing / o. Univ. Prof. Dipl. Ing. Dr. techn.
H. Peter Degischer
· Neue Materialien Fürth GmbH / Prof. Dr. R. F.
Singer
· LKR - Ranshofen (on-road test)
· MIT - Boston (Computation, Simulation)
Permanent Cooperation with:
Field of ActivitiesAluminium foam
For the production of foamed aluminium, Al pow-
der is mixed with a product releasing gas at higher
temperature and then compacted. This foaming
agent is placed into a mold form and heated up
until the agent starts to foam. Immediately there-
after the mold is taken out of the furnace and
cooled off, so the aluminium foam part is frozen
in shape. The outcome of this process is a closed
cell aluminium foam showing a thin casting skin
on the surface.
Powder Metallurgy
This technology is creating benchmarks. During
this process, metal powders are being compacted
using extrusion technologies. This represents an
additional technology besides existing sinter
technologies, especially for components with
2-Dimensional outlines. Material properties can be
designed precisely for requirements. Structural
parts with high stiffness, thanks to the various
possibilities of combining Non-Ferrous powders
can be named as example.
Application of Aluminium foamThe combination of top attributes such as high
stiffness, low weight and high energy absorption
enables Aluminum foam to qualify for specific
requirements within the automotive, aviation,
railway and engine building industry. Aluminium
foam is also qualifying for other high potential
applications in the field of Architecture and Design,
where electromagnetic shielding, structural dam-
ping, flame resistance and a decorative surface
structure is required.
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com
Characteristics
Product information 2.2.01.08/06 GB
· high stiffness at very low density
· Absorption of high impact energies, regardless
of the impact direction
· heat insulation
· highly efficient in sound absorption, electro-
magnetic shielding and vibration damping
· heat resistant and not inflammable
· fully recyclable
Summary of Results:
· the storage modulus of Alulight® does not
depend on resonant frequency – it can be consi-
dered as a static value of the modulus
· Alulight®’s modulus of elasticity depends strongly
on density. The dependence obeys the power
law function with an exponent of about 1.6
· the base alloy composition has no significant
influence on the modulus of elasticity of Alulight®
(tests with densities up to 1000 kg/m3).
Main Applications:
· stiff structural components with minimized
masses – especially beam and membrane-like
structures
· as a filling material for hollow structures Alulight®
helps to move resonant frequencies outside
operating frequency range
· heat resistant structures with high stiffness and
low density made at reasonable cost
· isotropic properties, non-combustibility, form
stability and simple recycling make it an alterna-
tive to wood (Alulight® floats on water)
· heat resistant, isotropic and stiff cores for sand-
wich structure
Material density p modulus E Elp2
[kg/m3] [GPa] [10-5 GPa.kg2/m6]
Alulight® 500 5 2,0
epoxy: 1300 3 0,3
steel: 7800 210 0,4
aluminium: 2700 69 1,0
glass: 2500 70 1,1
concrete: 2500 50 0,8
The structure modulus elasticity of foam cannot be determined as usual from the slope of the stress strain curve. This is due to plasticdeformations in the early stress stages. Elastic vibration loading is therefore the more appropriate method. Alulight® was testedas follows: The rod-shaped sample was vibrated longitudinally with an “impact-hammer”.Test sample: Alulight® rod-shaped specimens (diameter of 17 mm, min. length of 300 mm) with varying densities and base alloycompositions were used for the tests.
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com
Characteristics of Panels
Product information 2.2.01.02/04 GB
One has the choice between pure aluminium foam
and additionally reinforced panels with densities
ranging from 0,4–0,6 kg/dm3. Expanded metal
may be embedded within the aluminium foam in
order to improve bending stiffness.
Alulight®-sandwiches can also be produced with
plain or shaped aluminium cover sheets either on
one or both sides, if higher bending strength or
specific surface quality is required.
Pre-cut panels with outlines after customer require-
ments are available on request.
Alulight®-panels can be nailed, screwed, bolted
joint, using connection elements built in the foamed
structure or mounted using variety of standard
tools for wall, ceiling and floor mounting.
Deflection of Alulight®-panels and sandwiches
in comparison with Al sheet of the same weight
(four point bending test under various loads).
Test: hx 450 x 50 mm
Alulight® panels are available with casting skin in
various dimensions. Our panels can be machined
as easily as wood, using conventional techniques
like sawing, drilling, turning, etc.
Care should be taken, as the very thin surface skin
can be removed by machining, thus revealing the
inner pore structure.
Material AlSi AlMgSi0,6 AlMgSi0,6+T6
E-modulus: GPa 5 5 5
min. plastic collapse stress: MPa 7 7 12
min. bending stiffness: MPa 8 8 15
bending stiffness: % 210 210 210(Al-sheet, same weight)
heat conductivity at 20°C: W/m.K 6–15 6–15 6–15
electrical conductivity: 108 S/m 3 3 3
energy absorption: MJ/m3 4,5 4,5 9(20 MPa compressive stress)
loss factor: 0,003 0,003 0,003
Def
lect
ion
[m
m]
50 N
100 N
150 N
Deflection of Alulight®-panels and sandwiches:
9
8
7
6
5
4
3
2
1
0Alulight-sandwichone side h-13mm
Alulight-panelh-10mm
Alulight-panelh-8mm
Alulight-sandwichdouble sided h-10mm
Al-sheeth-3mm
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com
Density: 500–550 kg/m3.
Data were based on a closed geometry 50x50mm with a wall thickness by 7mm.
Energy Absorption
Product information 2.2.01.08/06 D
Impact absorbers protect passengers and fragiledevices from the effects of sudden impact. This isachieved by converting the impact energy intoplastic deformation energy, keeping the peak forceacting on the protected object below the levelwhich could cause damage. The material must alsoprovide a long deformation path to sufficientlyreduce the deceleration of the protected object.
The energy absorption properties can be adjustedthrough foam density respectively pore size andmay be optimized through further heat treatment.
Because of those excellent absorption propertiesAlulight® aluminium foams are already used asserial part for crash absorption by leading automo-tive manufactures.
Main Applications:
· deformable car body parts for protection of
passengers form crash (also side protection)
· safety pads for lifting and conveying systems
· protective covers for high speed rotating
machines
Summary of Results:
· Alulight®´s cell walls start to buckle (wrought
alloys) and fracture (cast alloys) at low stresses
allowing for extensive compression with an ade-
quate deceleration path
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com
100
90
80
70
60
50
40
30
20
10
0 10 20 30 40 50 60 70 80Deformation (%)
Load
(kN
)
100
90
80
70
60
50
40
30
20
10
0 10 20 30 40 50 60 70 80
Effic
ency
of
abso
rbtio
n (%
)
Deformation (%)
Example of compressive load- deformation and absorption efficiency- deformation curves of Alulight® for comparision between bulk Aluminium profile and aluminium foam as crash absorbers.
Al–profile: 1,75 kg/m
Al–foam: 1,3 kg/m
Co
mp
ress
ion
str
ess
(MPa
)
Deformation (%)
Both curves describe the minimum and maximum possibleenergy absorption of Alulight® depending on densityalloy and heat treatment.
Trial Samples:AlMgSi aluminium foamdensity 0,22 g/ccmØd= 25mml = 30mm
AlMgSi aluminium foamdensity 0,70 g/ccml x b x h = 47 x 55 x 35 mmHeat treated
Test MethodUniaxal compression testCompression speed: 3mm min
AlSi–foam–density 0,22 g/ccm
AlMgSi–foam–density 0,70 g/ccm-HT
Measuring of impact energy absorption:
40
35
30
25
20
15
10
5
00 10 20 30 40 50 60 70 80
Energy absorption by comparision
Measuring conditions: Al-foam: 55x55mm; 1,35kg/mAl-profil: 60x90x2,5mm; 1,75kg/m
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Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610e-mail: office@alulight.comInternet: www.alulight.com
Product information 2.2.01.02/04 GB
The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given.We reserve the right to alter any product data as a result of technical progress or further developments in the manufacturing process.
Design and architecture:
A process of design and modelling which also takes
into consideration the aesthetic aspects. Intuitive
creation of buildings and objects to raise emotions
through individual beauty.
With Alulight® a new, ageless material is available
to transfer theory and philosophy of sensual per-
ception into practice.
Due to the moulding capabilities of Alulight® there
is also the possibility to produce 3 dimensional
shapes.
Application potentials:
· furniture
· lay construction
· adornment for desks or chairs
· cladding constructions
· ceilling plates
· signboards with embossed text, letters or com-pany logos.
· fire protection / defence applications
Aesthetic with Attributes:
· 4 to 5 times lighter than bulk aluminium,stiffer than solid aluminium at the same weight
· each surface is individual
· flame resistante
· 100% recyclable
· good magnetic fields and electromagnetic wavesshielding efficiency
· lower thermal conductivity than solid aluminium
If required aluminium foam can be finished, coated
or also gummed. If a particular smooth surface is
desired the aluminium foam has to be primed
before lacquering to clear the roughness
of the textile like casting skin.
We are pleased to assist you by searching for special
lacquers, coatings or surface treatments.
Product information 2.2.01.08/06 GB
Main Applications:
· structural material for various cases gear boxes
or covers which suffer from mechanical vibrations
· damping material to fill hollow parts or profiles
Summary of Results:
· The loss factor of Alulight® is significant higher
than the loss factor of Aluminium
· The damping ability of aluminium foam allows
to reduce the noice iduced by vibrations
· damping ability of Alulight® depends insignifi-
cantly on resonant frequency
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63
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com
Resonance Decrease:
Structural damping is the effect of internal friction
within changing a material vibration energy into
heat. This reduces excessive noise and vibration by
converting them into heat to be expelled into the
surrounding area.
Vibration energy in cellular structures is dissipated
by the slight plastic deformation of the thin walls
separating the pores. It can also be reduced by
friction between the surfaces of cracks appearing
in the pore walls.
Damping factor (decay) of 25 mm Alulight® foampanel, 5 mm Al-sheet and 3 mm Al-sheet.
Trial samples:Al-foam: 500x500x25mm; 2kgAl-panel: 500x500x3mm; 1,9kgAl-panel: 500x500x5mm; 3,3kg
Test methodThe samples were exited in longitudinal vibration bythe „impact hammer“ method. The amplitude decaywas measured with an acceleration sensor and afrequency analyzer.
dec
ay-d
amp
ing
fac
tor
Eta
(-)
frequency f (Hz)
1,4E-02
1,2E-02
8,0E-03
6,0E-03
4,0E-03
2,0E-03
0,0E+00
500 1000 1500 2000 2500
Time vs. surface acceleration dependance, ability todamp vibration after impact by impact hammer
3mm Al-panel: 1,9 kg
Al-foam 25mm: 2,0 kg
5mm Al-panel: 3,3 kg
Damping factor
Vibration behavior
Acc
eler
atio
n (m
s-2)
Acc
eler
atio
n (m
s-2)
Acc
eler
atio
n (m
s-2)
Time (ms)
Time (ms) Time (ms)
Electromagnetic shielding
Product information 2.2.01.08/06 GB
Electromagnetic waves can cause malfunctions in
various electronic devices. Negative influence on
human health is also being investigated. Electro-
magnetic wave shielding should be used to protect
electronic devices and rooms interiors from elec-
tromagnetic waves.
The material for this purpose should possess good
electric conductivity to minimize the penetration
of waves into the material and low magnetic per-
meability to convert magnetic energy into heat.
Main Applications:
· cover boxes for electronic devices
· wall and ceiling plates for protection of rooms
against entering or releasing of electromagenetic
waves within the frequency range of 0,1 to
1000 MHz
Preliminary Results:
· Alulight® possesses very good magnetic field
shielding effectiveness.
· electric shielding effectiveness of Alulight® is
comparable with the one of silicon steel for
frequencies up to 10 MHz. Alulight® is superior
for higher frequencies.
· electromagnetic shield effectiveness of Alulight®
depends significantly on the frequency
Shie
ld e
ffec
tive
nes
s [d
B]
Frequency [MHz]
Electric field shielding effectiveness as a function
of frequency for samples of same weight.
Si-steel
Electric field shielding effectiveness:
140
120
100
80
60
40
20
00,1 1 10 100 1000
Alulight®
Test method:
Electric and magnetic shielding tests by KEC
method.
Trial sample:
Alulight®-sheets (140 x 140 x 8,5 mm) with the
density of 510 kg/m3 were used as specimens.
Silicon steel sheet (140 x 140 x 0,5 mm) and
bulk aluminium sheet(140 x 140 x 10 mm) were
used as reference materials.
Shie
ld e
ffec
tive
nes
s [d
B]
Frequency [MHz]Magnetic field shielding effectiveness as a function of frequency forsamples of same weight.
massive Al
Si-steel
Magnetic field shielding effectiveness:
140
120
100
80
60
40
20
00,1 1 10 100 1000
Alulight®
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com
Conductivitythermal / electric
Product information 2.2.01.08/06 GB
Only a small portion of Alulight®´s cross section is
conductive. These are the pore walls with the
conductivity value of the base alloy. The pore walls
are continiously covered with non-conductive alu-
mina. The main part of the cross section is formed
by the pores filled with air which is non-conductive.
Alulight® is therefore far less conductive than bulk
aluminium.
Main Applications:
· recyclable heat shields
· boxes for electronic devices, where also electro-
magnetic shielding or crash energy absorption
are important
Summary of Results / Electrical Conductivity:
· electric conductivity decreases with density of
Alulight®
· electric conductivity of Alulight® is a non-linear
Summary of Results / Thermal Conductivity:
· Thermal conductivity of Alulight® is only 1/10 of
that of base aluminium
The electric conductivity of Alulight® as a function of density (electricconductivity of massive Aluminium is 37/106 S/m-1)
Test method:
The electric conductivity was calculated from
the geometry and the resistance of the sample.
The resistance measurement was performed by
the four point method.
Trial sample:
Cylindrical specimens of Alulight® with various
densities were used ( Ø 17 mm, length 300 mm)
elec
tric
co
nd
uct
ivit
y [1
0-1
S/m
]
density [kg/m3]
Measuring of electric conductivity:
50
40
30
20
10
0
0,0 0,5 1,0 1,5 2,0 2,5 3,0
Test method:
Comparative method for different temperatures
up to 400°C.
Trial sample:
Cylindrical specimens of Alulight® with different
densities prepared from various Al-alloys were
used. The outer surface of the samples (Ø 25
mm, length 20 mm) was removed by electric
discharge machining.
Thermal conductivity of Alulight® as a function of density and base alloy
Ther
mal
co
nd
uct
ivit
y [W
/mK
]
Measuring of thermal conductivity:
250
200
150
100
50
0430 500 2700
Al
AlSi12
AlMgSi
density [kg/m3]
function of density and obeys the power-law de-
pendence with an exponent of 1.5
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The data in this application brochure correspond with the current status of our knowledge and experience. We do not assume any guaranty for the information given. We reserve theright to alter any product data as a result of technical progress or further developments in the manufacturing process.
Contact:
Alulight® International GmbH
Lach 22A-5282 RanshofenAustriaPhone: (+43) (7722) 64564-0Fax: (+43) (7722) 64564-610E-mail: office@alulight.comInternet: www.alulight.com