Integral Foam Molding of Light Metals Technology, Foam Physics and F
The development of cost-effective techniques to produce metal parts with integrated cellular structure is the newly developed process of integral foam molding. This book shows in three parts the technology, the fundamentals and the simulation models for t
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Carolin Koerner
Integral Foam Molding of Light Metals Technology, Foam Physics and Foam Simulation
With 143 Figures and 8 Tables
Dr. Carolin Koerner Univ. Erlangen-N¨urnberg Inst. Werkstoffwissenschaften Martensstr. 5 91058 Erlangen Germany
ISBN: 978-3-540-68838-9
e-ISBN: 978-3-540-68839-6
Engineering Materials ISSN: 1612-1317 Library of Congress Control Number: 2008929338 c 2008 Springer-Verlag Berlin Heidelberg This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable to prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover Design: M¨onnich, Max Printed on acid-free paper 9 8 7 6 5 4 3 2 1 springer.com
for Viktor and Walter
Preface A person with a new idea is a crank until the idea succeeds. Mark Twain Metal foams show outstanding properties: Low weight, high rigidity, high energy absorption capacity, high damping capacity, etc. They have attracted strong industrial and scientific interest during the last decade. A variety of methods has been developed to produce foams and the development of new, more sophisticated methods is still going on. On the one hand, there are only very few applications where metal foams can be directly employed without further processing. On the other hand, established metal foam production methods have one feature in common, they produce foam and not metal parts containing metal foam. In the majority of cases additional shaping and joining steps are necessary to transform the metal foam into a working functional element. In addition, the cellular structure demands for appropriate joining technologies which are often not yet available or expensive. As a result, the whole processing sequence is in general long and expensive. The logical consequence of the requirement to develop cost-effective techniques to produce metal parts with integrated cellular structure is the newly developed process of integral foam molding. Integral foam consists of a solid skin and a cellular core. This is the fundamental construction principle which is ubiquitous in biological systems, e. g. the human skull, as well as in technical solutions, e. g. sandwich constructions. The concentration of the material within the skin optimizes the moment of inertia and thus stiffness and strength. The development of metal based integral foam follows analogous paths as that of polym
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