Pore Size Control in Aluminium Foam by Standardizing Bubble Rise Velocity and Melt Viscosity

Abstract

In recent years, aluminium foams have found use in a wide range of applications. The properties of these foams, as good structural strength with light weight have made them as a promising structural material for aerospace industry. Foaming techniques (direct and indirect) are used to produce these foams. Direct foaming involves blowing of gas to create gas bubbles in the melt whereas indirect foaming technique uses blowing agents as metallic hydrides, which create hydrogen bubbles. Porosity and its distribution in foams directly affect its properties. This demands for more theoretical studies, to control such cellular structure and hence properties. In present work, we have studied the effect of gas bubble rise velocity and melt viscosity, on pore size and its distribution in aluminium foam. A 15 PPI aluminium foam, prepared using indirect foaming technique having porosity ∼86 % was used for study. In order to obtain metal foam, the bubble must not escape from the melt and should get entrapped during solidification. Our calculations suggest that bubble rise velocity and melt viscosity are responsible for vertical displacement of bubble in the melt. It is observed that melt viscosity opposes bubble rise velocity and help the bubbles to stay in the melt, resulting in porous structure.