Cellular Metals Manufacturing

H.N.G. Wadley
2002 Advanced Engineering Materials  
Manufacturing Methods Overview As the engineering applications of cellular metals grows, many methods for their manufacture are being developed. [1] They result in materials that can be classified by the size of their cells, variability in cell size (stochastic or periodic), the pore type (open or closed) and the relative density of the structure. Figure 1 summarizes the range of cell size and relative density for materials created by established and emerging manufacturing methods. Those with
more » ... gh relative density, r/ r s >0.5 (where r is the cellular metals density and r s is that of the solid from which it is made) include Gasars made by the solidification of metal-H 2 alloys [2] and expanded, entrapped gas materials. [3] Interest in the structural uses of both materials has declined because of the difficulty of creating the low relative densities (0.05±0.20) needed for these applications. [4] Manufacturing methods based upon the foaming of a liquid metal, either by injecting a gas (the CYMAT process) [5] or by the decomposition of gas releasing particles (e.g. the Alporus or Alulight materials) [6] are the most widely used for making stochastic cellular aluminum. Efforts are underway to extend the method to other metals. Both approaches result in closed cell stochastic foams with cell sizes in the 0.5 to 15 mm range and relative densities from 0.04 to 0.4.
doi:10.1002/1527-2648(20021014)4:10<726::aid-adem726>3.0.co;2-y fatcat:c25pjsh2e5enva3uexy4h2izri