DEVELOPMENT OF DIE-CAST CONSTRUCTIONAL PARTS WITH AL FOAM AND THEIR INDUSTRIAL IMPLEMENTATION

Metallic foams or composite structures are ideal components for multifunctional applications; main properties of interest are light weight, energy absorption and dumping capacity. Through the reported research, a novel processing is developed to produce cast aluminum parts with shaped aluminum foam inserts. As aluminum foams are now being mass produced, their cost effectiveness has grown and thus they became an attractive option for different new application via adaptation of different mass production methods. Such one is developed by the authors and presented in this article.

The technological development of high pressure die casting a bulk aluminum envelope around solid aluminum foam cores is envisaged. In orfer to obtain a good quality of composite cast structure and to minimize component defects, the basic processoing parameters such as molten metal and die temperaturs, lubricant tribology, pressures and gating system are re-evaluated and optimized. Furtherstages in the research`s technological processes will improve other industrial relevant factors such as computer aided design (CAD) of cast parts and mold, simulation tools for optimization of casting parameters, machining of the products and the foam inserts, inserts material optimization and rectcling of the products into foams or "bulk" aluminum.

Applications for such cast composite components are widelt spread within the transportaition sector wherein light weight light weight design of the vehicles saves fuel and decreases the environmental carbo foot-print of the materials, which decreases the CO₂ emission and makes them safer.

Furthermore, the impact absorption capacity is another important factor that can be added by using the foam-containing part. This will enable the market introduction of innocatiove aluminum parts with reduced weight and increased safety features.