AFS Library

Development of Alcoa Aluminum Foam Products

20082874
Journal: Proceedings of the Third International Conference on Light Metals Technology Sept 24-26 2007 Quebec, Canada P217-222
Author: J. Bryant, M. Crowley, W. Wang, D. Wilhelmy, D. Hunter

Aluminum foams have achieved only a fraction of market acceptance enjoyed by polymeric foams, even though aluminum foams offer the potential of superior service performance and improved environmental sustainability. This presentation describes a new light weight aluminum foam product developed at Alcoa Technical Center to capture this potential. Through the controlled decomposition of carbonate powders within molten aluminum, a stable, foamable suspension is created that resists both coalescence and drainage. A novel processing method provides for the economical production of wide panels of self-stabilized aluminum foam. The physical and mechanical properties of these fined celled aluminum foams are related to their cellular structure and the properties of these fined celled aluminum foams are related to their cellular structure and the properties of the aluminum alloy matrix from attractive combination of performance attributes, such as low density, high rigidity, high energy absorption and fire resistance, and contributes to Alcoa’s sustainability goals of energy efficiency and recycling through high aluminum scrap tolerance. A range of product applications incorporating Alcoa Aluminum Foam, n both monolithic form as well as a core material in laminate structure, is currently being studied for service in the building, construction and transportation markets. Performance of Alcoa Aluminum Foam products under different service conditions will be discussed.



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