Weight reduction
Because aluminum foam has a relatively small relative density and high specific stiffness, the components made of aluminum foam can meet the requirements of stiffness and greatly reduce the weight of automobiles. The density of aluminum foam is much lower than that of matrix material, and sometimes the voidage is even 99%. Aluminum foam has high specific strength and can produce reversible quasi elastic deformation. For defective aluminum foam, the elastic modulus and density have a function of the two power. For ideal closed cell aluminum foam, there is a linear relationship between elastic modulus and density. The less foam defects, the higher the elastic modulus of aluminum foam and the higher the stiffness.
The application of aluminum foam in automobile manufacturing is mostly foam sandwich structure. The foam aluminum sandwich structure includes aluminum foam sandwich panels, aluminum foam shaped parts and foam aluminum filling structures. The core layer of the foam aluminum sandwich structure is foam aluminum, and the inner and outer coating is aluminum or other metal plates. The two main factors for optimizing the design of aluminum foam sandwich structure are the thickness of the coating and the proper density of the new foam aluminum.
Foam aluminum plus laminate, the outer layer is stamped into the aluminum plate needed for shape, the middle is filled with aluminum powder and TiH2 (blowing agent) particles mixture. The mixture is melted into foam aluminum at high temperature and bonded to the outer aluminum plate. Its technological characteristics are that the components are formed before foaming at high temperature. The height of the body plate processed by this method is increased by 10 times, and the weight is reduced by 50%. The stiffness of the automobile hood made of foam sandwich plate instead of traditional steel plate is about 7 times the original steel structure and the quality is 25% smaller than that of the steel piece. The same method can also produce foam aluminum special-shaped parts.
Applications:
| making riot-proof vehicles | The compound armor of riot car is made of aluminum foam, and the weight of riot car can be reduced by more than 1/3. |
| Making Ordinary Train Floor | The foam aluminum floor of ordinary train is composed of 1mm aluminum sheet /15 ~ 20mm foam aluminum plate, /1mm aluminum plate sandwich board, and aluminum foam density is about 0.5g/cm3. It has excellent sound insulation and isolation function, no combustion, good fire resistance, bending strength of about 20 Mpa, service life of more than 30 years. Light weight, about 1/2 of the weight of the board. |
| Making High Speed Train Floor | The aluminum foam flooring for high-speed train is made of 1mm aluminum plate /25 ~ 30mm foam aluminum plate /1mm aluminum plate sandwich board, and the density of aluminum foam is about 0.5g/cm3. Over 20 dB sound insulation, vibration reduction by an order of magnitude, fire protection, corrosion resistance, bending strength of about 20 Mpa, no collapse, service life of more than 30 years. |
| Making Sandwich for Train Door | The foam aluminum plate is used as the door sandwich material. It has excellent functions of sound insulation, isolation and heat insulation, and is isotropic when bearing the load. |
| Making Carriage Lining |
20mm thick foam aluminum lining for subway cars can reduce noise by more than 20 decibels. The side lining of large train, high speed train and metro train adopts 20mm foam aluminum plate /20mm polyurethane foam composite board, which has excellent insulation and sound insulation capability. |
| Making compartment partition wall | Using foam aluminum plate to make passenger compartment partition, sound insulation and vibration isolation function is good, the intensity of each direction is consistent, intensity is good, does not produce birdsong sound. |
