Metallic foams are relatively unknown structural materials nevertheless with wide range of lightweight applications potential. Applications of metallic foams, especially aluminum, as panels, sandwiches, foamed hollow profiles and castings with foamed cores combines higher stiffness lightweight with acceptable manufacturing costs. Polymer and ceramic foams are widely used for isolations, filters or in packaging, However they cannot be used for constructional purposes due to insufficient rigidity (low elasticity modulus of polymers), or brittleness of ceramic. These issues lead to development of metallic foams based on lightweight metals, especially aluminum and its alloys. Several engineering properties of metallic foams are superior to those of polymeric foams, they are stiffer by an order of magnitude, they are stable by elevated temperatures, and they possess superior fire resistance and do not evolve toxic fumes in a fire. Foamed aluminum is generally considered as a system of dispersed gas in solid aluminum. It is an exceptionally lightweight material which has unique combination of high stiffness and low density. Various structural parts can be made of foamed aluminum not only in order to gain weight savings and keeping required stiffness, but also aiming to improve the noise reduction or heat insulation properties. Aluminum foams are also easily recyclable and ecologically harmless. Future lightweight application needs to offer combination of properties like weight decreasing and NVH improvement by cost effectiveness. The paper summarizes comparison of two different Al-foams materials filled into engine bracket structure, first is Alulight (Al powder + TiHi2) foam prepared by powder metallurgy (IMSAS Bratislava) and second advanced pores morphology (APM) foamed from cutted Al-Si wire (IFAM Bremen). NVH check by impact hammer test, 3D laser NVH test, FEM/CAE analysis and structure-borne sound by driving test are the published results. Investigation of bracket materials redesign (complete bracket made by Alulight Al-foam) shows NVH improvement at simultaneously decreasing of cost and weight.
Aluminum foam for engine bracket application
2014
15 Seiten, Bilder, Tabellen, 8 Quellen
Conference paper
Storage medium
English