A R C H I V E S
o
F O U N D R Y E N G I N E E R I N G
DOI: 10.1515/a e-2015-0038
Published qua e ly as he o gan o he Found y Commission o he Polish Academy o Sciences
ISSN (2299-2944)
Volume 15
Issue 2/2015
55 – 58
A R C H I V E S o F O U N D R Y E N G I N E E R I N G V o l u m e 1 5 , I s s u e 2 / 2 0 1 5 , 5 5 - 5 8 55
Manu ac u ing o Cas Me al Foams
wi h I egula Cell S uc u e
I. K oupo á*, F. Radko ský, P. Lichý, V. Bednářo á
* Depa men o Me allu gy and Found y Enginee ing, Facul y o Me allu gy and Ma e ials Enginee ing, VSB – Technical
Uni e si y o Os a a, 17. lis opadu 15/2172, 708 33 Os a a, Czech Republic
*Co esponding au ho . E-mail add ess: i ana.k oupo a@ sb.cz
Recei ed 21.03.2015; accep ed in e ised o m 31.03.2015
Abs ac
Me allic oams a e ma e ials o which he esea ch is s ill on-going, wi h he b oad applicabili y in many di e en a eas (e.g. au omo i e
indus y, building indus y, medicine, e c.). These me allic ma e ials ha e speci ic p ope ies, such as la ge igidi y a low densi y, high
he mal conduc i i y, capabili y o abso b ene gy, e c. The wo k is ocused on he p epa a ion o hese ma e ials using con en ional cas ing
echnology (in il a ion me hod), which ensu es apid and economically easible me hod o p oduc ion o shaped componen s. In he
expe imen al pa we s udied condi ions o cas ing o me allic oams wi h open po es and i egula cell s uc u e made o e ous and non-
e ous alloys by use o a ious ypes o ille ma e ial (p ecu so s).
Keywo ds: Me allic oam, P ecu so , Cas ing, I egula cell s uc u e
1. In oduc ion
Cellula ma e ials a e widesp ead in e e yday li e and a e
used o cushioning, insula ing, damping, cons uc ing, il e ing
pu poses and many o he applica ions. Highly po ous ma e ials
a e known o ha e a high s i ness combined wi h a e y low
speci ic weigh . Fo his eason cellula ma e ials equen ly occu
in na u e as cons uc ional ma e ials (e.g. woods and bones). The
ac ha e en me als and me allic alloys can be p oduced
as cellula solids o me al oams is no as well-known as he
possibili y o oam mo e adi ional enginee ing ma e ials such
as polyme s, ce amics o glass. Me allic oams o e in e es ing
pe spec i es due o he combina ion o p ope ies which a e
ela ed o he me allic cha ac e on he one and o he po ous
s uc u e on he o he hand [1].
2. Me hods o me allic oam p oduc ion
Since he disco e y o po ous me allic ma e ials nume ous
me hods o p oduc ion ha e been de eloped. Some echnologies
a e simila o hose o polyme oaming, o he s a e de eloped
wi h ega d o he cha ac e is ic p ope ies o me allic ma e ials,
such as hei abili y o sin e ing o he ac ha hey can be
deposi ed elec oly ically [2].
Acco ding o he s a e, in which he me al is p ocessed, he
manu ac u ing p ocesses can be di ided in o ou g oups. Po ous
me allic ma e ials can be made om [3, 4]:
 liquid me al (eg. di ec oaming wi h gas, blowing agen s,
powde compac mel ing, cas ing [5], sp ay o ming)
 powde ed me al (eg. sin e ing o powde s, ib es o hollow
sphe es, ex usion o polyme /me al mix u es, eac ion
sin e ing )
 me al apou s ( apou deposi ion)
 me al ions (elec ochemical deposi ion)
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56 A R C H I V E S o F O U N D R Y E N G I N E E R I N G V o l u m e 1 5 , I s s u e 2 / 2 0 1 5 , 5 5 - 58
Po osi y may achie e 30% o 93% depending on he me hod
o p oduc ion and ma e ial used. By changing he p ocess
pa ame e s i is possible o ob ain po ous s uc u e wi h a ious
sizes and shapes o po es and wi h di e en ypes o a angemen
( egula o i egula - s ochas ic) [3].
3. P ope ies and u iliza ion o me allic
oams
Foams and o he highly po ous ma e ials wi h cell s uc u e
a e known o a combina ion o many in e es ing physical and
mechanical p ope ies (Fig. 1).
Fig. 1. Applica ions o me allic oams [6]
4. Expe imen al
The a en ion in his wo k is paid o p epa a ion p ocesses
o me al oams om a liquid phase by a common ound y p ocess.
The use o inancially less cos ly me hods o manu ac u e o
cas ings om e ous and non- e ous me als oo will allow o ge
an a o dable ma e ial. A he same ime he ound y p ocess
enables he p oduc ion o highly complex pa s including hollow
cas ings. Expe imen al wo k is based on he manu ac u e o me al
oams wi h using p ecu so s. In his case o hei p epa a ion
such ma e ials we e used which a e commonly used nowadays in
ound ies o manu ac u e o moulds and co es.
4.1. In il a ion o mol en me al in o mould
illed wi h p ecu so s
In il a ion o me al in o he mold is made by pou ing o
liquid me al in o he mold illed wi h ino ganic o o ganic
pa icles. The i egula s uc u e o po es, we a e dealing wi h,
can be achie ed by use o a ious ypes o p ecu so s, which ill
he mould ca i y.
P ecu so s mus mee ce ain c i e ia. Pa icula ly, hey mus
be made o ma e ial, which p ese es i s shape a impac o he
mol en me al (su icien s eng h, low ab asion, e ac o iness)
and hey mus allow also good disin eg a ion a e cas ing.
The possibili y o con ol o he cellula s uc u e p oduced
(po e size, po osi y, e c.), is he e y impo an ad an age o he
use o a ound y echnique o manu ac u e me allic oams,
howe e he p ecu so s a e made.
In he expe imen we made cas ings wi h i egula cell
s uc u e wi h use o p ecu so s based on con en ional molding
mix u es (o ganic ypes).
4.2. P ecu so s - C oning p ocess
Co e pa icles we e hen manu ac u ed om molding mix u e
( espec i ely om ejec co es made by C oning p ocess). Final
globula shape o co e p ecu so s was achie ed by spli ing in o
small pieces (10 – 30 mm) and ollowed by umbling. A mould
ca i y was illed wi h hese p ecu so s. Mold was made om
commonly used g een sand (i.e. ben oni e bonded molding
mix u e) - see Fig. 2 - 4.
Fig. 2. Mold made om
commonly used g een sand
Fig. 3. Mold illed wi h
p ecu so s
Fig. 4. Final cas ing and de ail o i s s uc u e
Po osi y o p oduced cas ings amoun ed o 60%. P ecu so s
allow good disin eg a ion a e cas ing.
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A R C H I V E S o F O U N D R Y E N G I N E E R I N G V o l u m e 1 5 , I s s u e 2 / 2 0 1 5 , 5 5 - 58 57
The disad an age o hese p ecu so s is hei i egula shape,
which is de e mined by une en umbling o he culle due
o nonuni o m ha dening o he de aul co e mix u e. The e o e,
new echnology o p ecu so s manu ac u ing has been p oposed –
use o molding mix u e bonded by u an esin. This way
o manu ac u ing o p ecu so s should ensu e he achie emen o
he same size, shape and he esul ing cha ac e is ics o
p ecu so s.
4.3. P ecu so s – Fu an molding mix u e
To c ea e hese p ecu so s we e used as co e box plas ic g ille
(Fig. 5). By using his co e box cubes o a side o 25 mm we e
c ea ed. These cubes we e ollowed by umbling. The p oposed
echnology ensu es he p oduc ion o p ecu so s o he same size,
shape and p ope ies.
Ma e ials used o e cas ing we e cas i on wi h lamella
g aphi e (EN GJL-200), AlSi10MgMn [7] and CuSn10 (see Fig. 6
– 9) .The e we e wo ypes o cas ings – a cuboid (I) and a
cylinde (II).
Fig. 5. Co e box and c ea ed cubes
Fig. 6. Cas ing (cas i on wi h lamella g aphi e) – ype I
Fig. 7. Cas ing (cas i on wi h lamella g aphi e) – ype II
Fig. 8. Cas ing (CuSn10) – ype I
Fig. 9. Cas ing (AlSi10MgMn) – ype II
Po osi y o p oduced cas ings amoun ed o 63%. P ecu so s
allow good disin eg a ion a e cas ing.
On he Fig. 10 and 11 we can see a compa ison o he wo
ypes o p ecu so s.
Fig. 10. P ecu so s – C oning p ocess (i egula shape and size)
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58 A R C H I V E S o F O U N D R Y E N G I N E E R I N G V o l u m e 1 5 , I s s u e 2 / 2 0 1 5 , 5 5 - 58
Fig. 11. P ecu so s – Fu an molding mix u e ( egula shape and
size)
5. Conclusions
Me al oams a e p og essi e ma e ials wi h con inuously
expanding use. Mas e ing o p oduc ion o me allic oams wi h
de ined s uc u e and p ope ies using g a i y cas ing in o sand
o me allic ound y moulds will con ibu e o an expansion o he
asso men p oduced in ound ies by comple ely new ype o
ma e ial, which has unique se ice p ope ies hanks o i s
s uc u e, and which ul ils he cu en demanding ecological
equi emen s. Manu ac u e o oams wi h he aid o g a i y
cas ing in con en ional ound y moulds is a cos ad an age
p ocess which can be indus ially used in ound ies wi hou high
in es men demands.
The p inciple o he abo e-men ioned echnology is he
in il a ion o liquid me al in o he mold ca i y illed wi h
p ecu so s. This echnology enables he p oduc ion o shaped
cas ings – me allic oams wi h i egula cell s uc u e. In he
p oduc ion o p ecu so s can mo eo e be assumed using o he
ma e ial, which would be in o he cases was e - ejec co es o
excess molding mix u e.
Acknowledgemen s
This wo k was elabo a ed wi hin he esea ch p ojec
TA02011333 suppo ed by he Technology Agency o he Czech
Republic and p ojec o speci ic esea ch VŠB-TU Os a a – SP
2015/78 and SP 2015/70.
Re e ences
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[6] F om h p://www.auli e.com/blog/2014/03/26/3-ways-how-
pa en s-can-help- o- ind-new-clien s-ma ke s-and-
applica ions/
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