Functionally Graded Aluminum Foam Fabricated by Friction Powder Sintering Process with Traversing Tool

• Published in: Journal of materials engineering and performance 2016-09, Vol.25 (9), p.3691-3696
• Main Authors: Hangai, Yoshihiko, Morita, Tomoaki, Koyama, Shinji, Kuwazuru, Osamu, Yoshikawa, Nobuhiro
• Format: Article
• Language: English
• Subjects: Characterization and Evaluation of Materials; Chemistry and Materials Science; Corrosion and Coatings; Engineering Design; Materials Science; Quality Control; Reliability; Safety and Risk; Tribology
• ISSN: 1059-9495; 1544-1024
• DOI: 10.1007/s11665-016-2218-x

Functionally graded aluminum foam (FG Al foam) is a new class of Al foam in which the pore structure varies over the foam, resulting in corresponding variations in the mechanical properties of the foam. In this study, FG Al foam plates were fabricated by a friction powder sintering (FPS) process with a traversing tool that is based on a previously developed sintering and dissolution process. The variation of the mechanical properties was realized by setting the volume fraction φ of NaCl in the mixture to 60, 70, and 80%. Long FG Al foam plates were fabricated with a length equal to the tool traversing length with φ varying in the tool traversing direction. From x-ray computed tomography observation, it was shown that the density of the Al foam decreased with increasing φ . In contrast, almost uniform pore structures were obtained in each area. According to the results of compression tests on each area, the plateau stress and energy absorption tended to decrease with increasing φ . Therefore, it was shown that FG Al foam plates with varying mechanical properties can be fabricated by the FPS process with the traversing tool.