Abstract
This chapter succinctly presents manufacturing processes for metallic foams. Nine manufacturing process are patented but only five major processes are successfully deployed for commercial purposes. Several manufacturing companies are tirelessly working on conventional and non-conventional approach targeting primarily for more efficient, reliable, reproducible, and low investment production system. These manufacturing systems target separately open-cell and closed-cell metal foams. As historically established in the area of materials science, metal foam properties depend critically on the type of base metal and manufacturing process. The present chapter also provides the glimpse of role of processing parameters which are critical in reproducing the structure and properties of foams. Present chapter also highlights the challenges in the production of metal foams.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Banhart, J. (2001). Manufacture, characterization and application of cellular metals and metal foams. Progress in Materials Science, 46(6), 559–632.
Banhart, J. (1999). Metal foams and porous metal structures. Berlin: MIT-Verlag.
Banhart, J., Ashby, M. F., & Fleck, N. A. (2001). Cellular metals and metal foaming technology. Berlin: MIT-Verlag.
Banhart, J., Fleck, N. A., & Mortensen, A. (2003). Cellular metals: Manufacture, properties, applications. Berlin: MIT-Verlag.
Degischer, H.-P., & Kriszt, B. (2010). Handbook of cellular metals: Production, processing, applications. Wiley-InterScience.
**, et al. (1990). Method of producing lightweight foamed metal. US Patent No. 4,973,358.
**, et al. (1992). Stabilized metal foam body. US Patent No. 5,112,697.
**, et al. (1993). Lightweight metal with isolated pores and its production. US Patent No. 5,221,324.
Kenny, et al. (1994). Process for shape casting of particle stabilized metal foam. US Patent No. 5,281,251.
Niebyski, et al. (1974). Preparation of metal foams with viscosity increasing gases. US Patent No. 3,816,952.
Miyoshi, T., Itoh, M., Akiyama, S., & Kitahara, A. (1998). Aluminum foam, ALPORAS, the production process, properties and applications. Shinko Wire Company, Ltd.
Thomas, et al. (1997). Particle-stablilized metal foam and its production. US Patent No. 5,622,542.
Akiyama, et al. (1987). Foamed metal and method of producing same. US Patent No. 4,713,277.
Elliot, J. C. (1956). Method of producing metal foam. US Patent No. 2,751,289.
ERG Inc. Oakland, USA. Duocel® Aluminum Foam–ERG Aerospace. (https://www.ergaerospace.com) (Access on 13/03/2019).
Schwartz, D. S., & Shih, D.S. (1998). Titanium foams made by gas entrapment. In D. S Schwartz, D. S. Shih, A. G. Evans, & H. N. G. Wadley (Eds.), Porous and cellular materials for structural application. Materials Research Society Proceedings, 521, MRS, Warrendale, PA, USA.
Sang, et al. (1994). Process for producing shaped slabs of particle stabilized foamed metal. US Patent No. 5,334,236.
Paserin, V., Marcuson, S., Shu, J., & Wilkinson, D. S. (2004). CVD Technique for inco nickel foam production. Advanced Engineering Materials, 6(6), 454–459.
Akiyama, S., Ueno, H., Imagawa, K., Kitahara, A., Nagata, S., Morimoto, K., et al. (1986). Foamed metal and method of producing same. U.S. Patent 4,713,277.
Baumeister J. (1991). Methods for manufacturing foamable metal bodies. US Patent 5,151,246.
Ashby, M. F., Evans, A. G., Fleck, N. A., Gibson, L. J., Hutchinson, J. W., & Wadley, H. N. G. (n.d.). Metal Foams: A Design Guide. 263.
Yu, C. J., & Eifert, H. (1998). Metal foams. Advanced Materials & Processes, 45–47.
MEPURA. (1995). ‘Alulight’ Metallpulver GmbH. Brannau-Ranshofen, Austria.
Quadbeck, P., Kümmel, K., Hauser, R., Standke, G., Adler, J., & Stephani, G. (2010) Open cell metal foams-application-oriented structure and material selection, 10.
Bart-Smith, H., Bastawros, A.-F., Mumm, D. R., Evans, A. G., Sypeck, D. J., & Wadley, H. N. G. (1998). Compressive deformation and yielding mechanisms in cellular Al alloys determined using X-ray tomography and surface strain map**. Acta Materialia, 46(10), 3583–3592.
Kottar, A., Kriszt, B., & Degisher, H. P. (1999). Shear test in flatwise plane of flat sandwich constructions or sandwich cores. Philadelphia, PA: American Society for Testing and Materials.
ASTM E8 / E8M-16ae1. (2016) Standard Test Methods for Tension Testing of Metallic Materials, ASTM International, West Conshohocken, PA.
Andrews, E., Sanders, W., & Gibson, L. J. (1999). Compressive and tensile behaviour of aluminum foams. Materials Science and Engineering: A, 270(2), 113–124.
Andrews, E. W., Gioux, G., Onck, P., & Gibson, L. J. (2001). Size effects in ductile cellular solids. Part II: Experimental results. International Journal of Mechanical Sciences, 43(3), 701–713.
Bastawros, A., & McManuis, R. (1998). Case study: Use of digital image analysis software to measure non-uniform deformation in cellular aluminum alloys. Experimental Techniques, 22(2), 35–37.
Brigham, E. O. (1988). The fast Fourier transform and its applications. Prentice Hall.
Chen, D. J., Chiang, F. P., Tan, Y. S., & Don, H. S. (1993). Digital speckle-displacement measurement using a complex spectrum method. Applied Optics, 32(11), 1839.
Instron. (1997). Surface displacement analysis user manual.
Deshpande, V. S., & Fleck, N. A. (2000). Isotropic constitutive models for metallic foams. Journal of the Mechanics and Physics of Solids, 48(6–7), 1253–1283.
Gioux, G., McCormack, T. M., & Gibson, L. J. (2000). Failure of aluminum foams under multiaxial loads. International Journal of Mechanical Sciences, 42(6), 1097–1117.
Hutmacher, D. W. (2001). Scaffold design and fabrication technologies for engineering tissues-state of the art and future perspectives. Journal of Biomaterials Science, Polymer Edition, 12(1), 107–124.
Banhart, J., & Seeliger, H. W. (2012). Recent trends in aluminum foam sandwich technology. Advanced Engineering Materials, 14(12), 1082–1087.
Neugebauer, R., & Hipke, T. (2006). Machine tools with metal foams. Advanced Engineering Materials, 8(9), 858–863.
Baumeister, J., Banhart, J., & Weber, M. (1997). Aluminium foams for transport industry. Materials & Design, 18(4–6), 217–220.
Schäffler, P., Hanko, G., Mitterer, H., & Zach, P. (2008). Alulight metal foam products. In Proceedings of the Porous Metals and Metallic Foams. The Japan Institute of Metals Kyoto, Japan, 7–10.
Eshraghi, S., & Das, S. (2010). Mechanical and microstructural properties of polycaprolactone scaffolds with one-dimensional, two-dimensional, and three-dimensional orthogonally oriented porous architectures produced by selective laser sintering. Acta Biomaterialia, 6(7), 2467–2476.
Partee, B., Hollister, S. J., & Das, S. (2006). Selective laser sintering process optimization for layered manufacturing of CAPA® 6501 polycaprolactone bone tissue engineering scaffolds. Journal of Manufacturing Science and Engineering, 128(2), 531–540.
Truscott, M., de Beer, D., Vicatos, G., Hosking, K., Barnard, L., Booysen, G., & Ian Campbell, R. (2007). Using RP to promote collaborative design of customised medical implants. Rapid Prototy** Journal, 13(2), 107–114.
Faustini, M. C., Neptune, R. R., Crawford, R. H., & Stanhope, S. J. (2008). Manufacture of passive dynamic ankle-foot orthoses using selective laser sintering. IEEE Transactions on Biomedical Engineering, 55(2), 784–790.
Fukuda, A., Takemoto, M., Saito, T., Fujibayashi, S., Neo, M., Pattanayak, D. K., et al. (2011). Osteoinduction of porous Ti implants with a channel structure fabricated by selective laser melting. Acta Biomaterialia, 7(5), 2327–2336.
Wang, Y., Shen, Y., Wang, Z., Yang, J., Liu, N., & Huang, W. (2010). Development of highly porous titanium scaffolds by selective laser melting. Materials Letters, 64(6), 674–676.
Gohler, H., Jehring, U., Kuemmel, K., Meinert, J., Quadbeck, P., Stephani, G., et al. (2012). Metallic hollow sphere structures—Status and outlook. In Proceedings of Cellular Materials—CellMat 2012, 07.09. November 2012, Dresden.
Shapovalow, V. I. (1993). US Patent 5,181, 549.
Banhart, J. (2000). Metallic foams: Challenges and opportunities (pp. 13–20). Berlin: MIT-Verlag.
Korner, C., & Singer, R. F. (2000). Processing of metal foams—Challenges and opportunities. Microstructural Investigation and Analysis: Wiley-VCH Verlag GmbH, Weinheim.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Copyright information
© 2020 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
About this chapter
Cite this chapter
Rajak, D.K., Gupta, M. (2020). Manufacturing Methods of Metal Foams. In: An Insight Into Metal Based Foams. Advanced Structured Materials, vol 145. Springer, Singapore. https://doi.org/10.1007/978-981-15-9069-6_3
Download citation
DOI: https://doi.org/10.1007/978-981-15-9069-6_3
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-15-9068-9
Online ISBN: 978-981-15-9069-6
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)