Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding

An emerging and still poorly explored application of aluminum foams is their potential use as permanent cores (inserts) in the casting of aluminum alloys. In this context, Al-based foams can introduce a weight reduction, the obtainment of cavities, a strength increase, the ability to absorb impact e...

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Autores principales:	Sara Ferraris, Antonio Santostefano, Antonio Barbato, Roberto Molina, Graziano Ubertalli
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	aluminum foam casting foam core porosity metallurgical bonding Mining engineering. Metallurgy TN1-997
Acceso en línea:	https://doaj.org/article/bbe714491823465cbaf3c648afc64309
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id	oai:doaj.org-article:bbe714491823465cbaf3c648afc64309
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spelling	oai:doaj.org-article:bbe714491823465cbaf3c648afc643092021-11-25T18:21:26ZAl-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding10.3390/met111117152075-4701https://doaj.org/article/bbe714491823465cbaf3c648afc643092021-10-01T00:00:00Zhttps://www.mdpi.com/2075-4701/11/11/1715https://doaj.org/toc/2075-4701An emerging and still poorly explored application of aluminum foams is their potential use as permanent cores (inserts) in the casting of aluminum alloys. In this context, Al-based foams can introduce a weight reduction, the obtainment of cavities, a strength increase, the ability to absorb impact energy and vibration, acoustic insulation ability, the possibility to simplify the technological processes (no removal/recycling of traditional sand cores), and finally, they can be fully recyclable. Cymat-type Al foams with thin outer skin were used as permanent cores in Al-alloy gravity casting in the present research. Al-foams were characterized in terms of porosity, density, cell wall and skin thickness, surface chemical composition and morphology, and compression resistance. Cast objects with foam inserts were characterized by means of optical microscopy. The preservation of up to 50% of the initial porosity was observed for foam inserts with higher density. Metallurgical bonding between the foam core and the cast metal was observed in some regions.Sara FerrarisAntonio SantostefanoAntonio BarbatoRoberto MolinaGraziano UbertalliMDPI AGarticlealuminum foamcastingfoam coreporositymetallurgical bondingMining engineering. MetallurgyTN1-997ENMetals, Vol 11, Iss 1715, p 1715 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	aluminum foam casting foam core porosity metallurgical bonding Mining engineering. Metallurgy TN1-997
spellingShingle	aluminum foam casting foam core porosity metallurgical bonding Mining engineering. Metallurgy TN1-997 Sara Ferraris Antonio Santostefano Antonio Barbato Roberto Molina Graziano Ubertalli Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding
description	An emerging and still poorly explored application of aluminum foams is their potential use as permanent cores (inserts) in the casting of aluminum alloys. In this context, Al-based foams can introduce a weight reduction, the obtainment of cavities, a strength increase, the ability to absorb impact energy and vibration, acoustic insulation ability, the possibility to simplify the technological processes (no removal/recycling of traditional sand cores), and finally, they can be fully recyclable. Cymat-type Al foams with thin outer skin were used as permanent cores in Al-alloy gravity casting in the present research. Al-foams were characterized in terms of porosity, density, cell wall and skin thickness, surface chemical composition and morphology, and compression resistance. Cast objects with foam inserts were characterized by means of optical microscopy. The preservation of up to 50% of the initial porosity was observed for foam inserts with higher density. Metallurgical bonding between the foam core and the cast metal was observed in some regions.
format	article
author	Sara Ferraris Antonio Santostefano Antonio Barbato Roberto Molina Graziano Ubertalli
author_facet	Sara Ferraris Antonio Santostefano Antonio Barbato Roberto Molina Graziano Ubertalli
author_sort	Sara Ferraris
title	Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding
title_short	Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding
title_full	Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding
title_fullStr	Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding
title_full_unstemmed	Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding
title_sort	al-based foams as permanent cores in al castings: effect of surface skin thickness and composition on infiltration and core-shell bonding
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/bbe714491823465cbaf3c648afc64309
work_keys_str_mv	AT saraferraris albasedfoamsaspermanentcoresinalcastingseffectofsurfaceskinthicknessandcompositiononinfiltrationandcoreshellbonding AT antoniosantostefano albasedfoamsaspermanentcoresinalcastingseffectofsurfaceskinthicknessandcompositiononinfiltrationandcoreshellbonding AT antoniobarbato albasedfoamsaspermanentcoresinalcastingseffectofsurfaceskinthicknessandcompositiononinfiltrationandcoreshellbonding AT robertomolina albasedfoamsaspermanentcoresinalcastingseffectofsurfaceskinthicknessandcompositiononinfiltrationandcoreshellbonding AT grazianoubertalli albasedfoamsaspermanentcoresinalcastingseffectofsurfaceskinthicknessandcompositiononinfiltrationandcoreshellbonding
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Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding

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