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Solid mold investment casting – A replication process for open-cell foam metal production

  • Kerem Altug Guler
Veröffentlicht/Copyright: 31. August 2015
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Materials Testing
Aus der Zeitschrift Materials Testing Band 57 Heft 9

Abstract

Foam metals have always been an interesting material type because of their unique properties and various production techniques. In this study, solid mold investment casting process, which is one of the replication techniques, was used to produce open-cell aluminum foam specimens. Commercial rubber sponge was tested as foam pattern material. Plaster bonded solid molds were prepared in the stainless steel flasks and infiltration of the slurry into the rubber sponge was carried out under vacuum. Following this, pattern removal and mold firing was carried out gradually. Molten A319 casting and A6063 wrought aluminum alloys were cast into flash molds with vacuum assistance (−105 Pa). Sponge pattern and cast foam specimens were examined and compared by stereo microscope and scanning electron microscope (SEM). It is clearly found that rubber sponge is a very suitable pattern material for producing open-cell foam structures.

Kurzfassung

Metallschäume sind auf Grund ihrer einzigartigen Eigenschaften und verschiedener Produktionsverfahren schon immer eine interessante Werkstoffklasse. In der diesem Beitrag zugrunde liegenden Studie wurde das Festformfeingießen als Replikationsprozess eingesetzt, um offenporige Aluminiumschaumproben herzustellen. Hierzu wurde ein kommerziell erhältlicher Gummischwamm als Schaummuster verwendet. Es wurden verklebte feste Plastikformen in hochlegierten Stahlbehältern vorbereitet und das Einsickern des Breis in den Gummischwamm unter Vakuum vorgenommen. Nacheinander wurde das Entfernen des Behälters und das Abbrennen der Form durchgeführt. Es wurden geschmolzene A 319 Gusslegierungen und A 6063 Knetlegierungen aus Aluminium unter Vakuum (−105 Pa) in die Überlaufformen gegossen. Die Schwammstruktur und die gegossenen Schaumproben wurden untersucht und mittels Stereomikroskop und Rasterelektronenmikroskop (REM) verglichen. Diese Untersuchungenergaben eindeutig, dass der Gummischwamm ein sehr geeignetes Strukturmaterial zur Produktion von offenporigen Metallschaumstrukturen ist.

§Correspondence Address, Assistant Prof. Dr. Kerem Altug Guler, Department of Metallurgical and Material Engineering, Yildiz Technical University, Davutpasa Campus, 34210 Esenler, Istanbul, Turkey. E-mail:

Kerem Altug Guler, born in 1981, is Assistant Professor at the Yildiz Technical University, Istanbul, Turkey. He received his MSc degree and his PhD degree in Materials Science from Yildiz Technical University in 2005 and 2012, respectively. He is working on several casting techniques such as investment casting and lost foam casting, and he also does research on metal matrix composites and cellular metals.

References

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Published Online: 2015-08-31
Published in Print: 2015-09-01

© 2015, Carl Hanser Verlag, München

Artikel in diesem Heft

  1. Inhalt/Contents
  2. Inhalt
  3. Fachbeiträge/Technical Contributions
  4. Adhesive tensile testing of atmospheric plasma sprayed zinc coating on a 1.4301 substrate
  5. Fatigue strength of nodular cast iron with regard to heavy-wall applications
  6. Mechanical and corrosion properties of friction stir welded joints of Al-Cu alloy 2219-T87
  7. The effect of using heat treated ulexite and cashew in automotive friction materials
  8. Residual stress relaxation in welded large components
  9. Variation regulation of the acoustic emission energy parameter during the failure process of granite under uniaxial compression
  10. Iznik tiles: A new production technology and respective characterization
  11. Quality during milling of a glass fiber reinforced polymer composite
  12. Effect of abrasive water jet turning process parameters on surface roughness and material removal rate of AISI 1050 steel
  13. Influence of cutting parameters on the chip-tool interface temperature during the turning of Waspaloy
  14. Effects of the thixocasting injection velocity on tensile properties of an A357 Al alloy
  15. Solid mold investment casting – A replication process for open-cell foam metal production
  16. Design of an impact testing machine for polymer films by the free falling dart procedure
  17. Mechanical and electrical properties of Sb-Ga50Au10In40 alloys
  18. CFD simulation of particulate flow in a spiral concentrator
https://doi.org/10.3139/120.110769

Artikel in diesem Heft

  1. Inhalt/Contents
  2. Inhalt
  3. Fachbeiträge/Technical Contributions
  4. Adhesive tensile testing of atmospheric plasma sprayed zinc coating on a 1.4301 substrate
  5. Fatigue strength of nodular cast iron with regard to heavy-wall applications
  6. Mechanical and corrosion properties of friction stir welded joints of Al-Cu alloy 2219-T87
  7. The effect of using heat treated ulexite and cashew in automotive friction materials
  8. Residual stress relaxation in welded large components
  9. Variation regulation of the acoustic emission energy parameter during the failure process of granite under uniaxial compression
  10. Iznik tiles: A new production technology and respective characterization
  11. Quality during milling of a glass fiber reinforced polymer composite
  12. Effect of abrasive water jet turning process parameters on surface roughness and material removal rate of AISI 1050 steel
  13. Influence of cutting parameters on the chip-tool interface temperature during the turning of Waspaloy
  14. Effects of the thixocasting injection velocity on tensile properties of an A357 Al alloy
  15. Solid mold investment casting – A replication process for open-cell foam metal production
  16. Design of an impact testing machine for polymer films by the free falling dart procedure
  17. Mechanical and electrical properties of Sb-Ga50Au10In40 alloys
  18. CFD simulation of particulate flow in a spiral concentrator
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