Pilot Production and Properties of ALUHAB Aluminium Foams

Abstract ALUHAB is a new type of aluminium foams with controlled, homogeneous cell sizes which has a wide range of alloy compositions, and attractive mechanical properties. The technology results in extremely stable metal foams which can be cast into complex forms and re-melted without loss of foam integrity. ALUHAB aluminium foams are manufactured from aluminium alloy containing ultrafine particles (typically below 3 μm). Special high temperature admixing technology is used in order to homogeneously disperse the particles and thus create a stable, foamable aluminium melt. Our unique loud-nozzle technology permits the injection of bubbles with optimal size which can vary between 0.5 mm and 5 mm. CT imaging, different analytical techniques and mechanical tests were used to characterize the influence of the alloy composition and the cell structure on the compression properties. Our recent pilot plant technology is capable to produce 100 kg/day aluminium foam block of maximum 200 mm width and the thickness can be varied from 20 mm to 50 mm.