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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2010

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Thixoinfiltration: a new approach to produce cellular and other low density metallic materials

Robert M. H., Jorge A. F., Gatamorta F., Silva R. R.

Journal of Achievements in Materials and Manufacturing Engineering

2010

Vol. 40, nr 2

180-187

Purpose: the work presents an innovative approach for the production of cellular metallic materials as well as low density metal matrix composites, by using thixoforming techniques; thixotropic semisolid metal is infiltrated into removable and non-removable space holder preforms. Different kinds of preforms are tested to obtain open cell material (sponges), syntactic foams and low density composites. Products are evaluated concerning relative density and mechanical behavior under compressive stresses. Design/methodology/approach: Al alloy AA2011 was infiltrated in the semisolid state into preforms of sintered NaCl particles, sintered glass spheres, vermicular ceramic particles and porous ceramic granulates. After solidification, preforms were either removed by leaching (NaCl) resulting in open cell cellular product, or not (all others), resulting in composites of low density. Tomography tests were used to observe internal quality, and semi-static and dynamic compression tests were performed to evaluate the deformation ability of the material. Findings: results show that thixoinfiltration is a simple and low cost technique to produce different types of low density, porous material. Open cell material as well as syntactic foams and low density composites can be produced with reliable internal quality and dispersion of cells and reinforcement. Composites containing porous reinforcements can present some mechanical characteristics of the conventional cellular metals. Research limitations/implications: as all new developments, the complete understanding of the influence of processing variables upon the final quality of the product, as well as its consistency, must be provided before the technology can be widely used commercially. Practical implications: the technique can represent an alternative, low cost processing route for the fabrication of sponges, foams and low density composites, which can avoid restrictions and operational difficulties of presently available manufacturing processes based in liquid manipulation or powder sintering methods. Originality/value: infiltration of appropriate preforms by thixotropic metallic alloys to produce low density composites and cellular material is a new technique under development by the proposing group at FEM/UNICAMP.