Review
BibTex RIS Cite

A Review on Welding Techniques of Metallic Foams

Year 2022, Volume: 15 Issue: 1, 217 - 232, 27.03.2022
https://doi.org/10.18185/erzifbed.997743

Abstract

Metallic foams are a new type of material class using in the much-diversified area such as automotive, biomedical, and construction etc. Thanks to its porous structure, it stands out with its energy and impact absorption as well as its lightness. Due to the properties, metal foams have the potential for use in many applications. As the number of uses and potential applications increases, it becomes important to develop adequate joining technologies for metallic foams and to select appropriate methods for their widespread industrial use. However, various problems are encountered in welding metallic foams with a foam or a face sheet. The most important feature that causes differences in the welding process and characteristics of these materials is porosity. While the methods such as MIG/TIG could be preferred in the past, the methods such as laser welding have come to the fore with today's needs. The welding of metallic foams is a subject that is still being studied and developed. In this study, studies in the literature are examined to understand the problems encountered in metallic foams during welding and to develop welding techniques. It is aimed to create a wide source for the welding of metallic foams by referring to the methods used and the advantages and disadvantages of the methods with this review.

References

  • Ashby, M. F., Evans, T., Fleck, N. A., Hutchinson, J. W., Wadley, H. N. G., and Gibson, L. J. (2000). “Metal foams: a design guide”, Elsevier.
  • Banhart, J. 2001. “Manufacture, characterisation and application of cellular metals and metal foams”, Progress in materials science, 46(6), 559-632.
  • Banhart, J. 2005. “Aluminium foams for lighter vehicles”. International Journal of vehicle design, 37(2-3), 114-125.
  • Banhart, J., and Seeliger, H. W. 2007. “Aluminium foam sandwich panels: metallurgy, manufacture and applications”. In 5th Biennial International Conference on Porous Metals and Metallic Foams (MetFoam 2007).
  • Banhart, J., and Seeliger, H. W. 2008. “Aluminium foam sandwich panels: manufacture, metallurgy and applications”, Advanced Engineering Materials, 10(9), 793-802.
  • Banhart, J., Seeliger, W., & Beichelt, C. (2002). Sandwich Panels, Handbook of Cellular Metals Production, Processing, Applications, 113-125.
  • Born, C., Kuckert, H., Wagner, G., & Eifler, D. (2003). Ultrasonic torsion welding of sheet metals to cellular metallic materials. Advanced Engineering Materials, 5(11), 779-786.
  • Born, C., Wagner, G., & Eifler, D. (2006). Ultrasonically welded aluminium foams/sheet metal–joints. Advanced Engineering Materials, 8(9), 816-820.
  • Burzer, J., Bernard, T., & Bergmann, H. W. (1998). Joining of aluminium structures with aluminium foams. In MATERIALS RESEARCH SOCIETY SYMPOSIUM PROCEEDINGS (Vol. 521, pp. 159-164). MATERIALS RESEARCH SOCIETY.
  • Bušić, M., Kožuh, Z., Klobčar, D., & Samardžić, I. (2016). Friction stir welding (FSW) of aluminium foam sandwich panels. Metalurgija, 55(3), 473-476.
  • Changdar, A., & Chakraborty, S. S. (2021). Laser processing of metal foam-A review. Journal of Manufacturing Processes, 61, 208-225.
  • Feng, M. N., Xie, Y., Zhao, C. F., & Luo, Z. (2018). Microstructure and mechanical performance of ultrasonic spot welded open-cell Cu foam/Al joint. Journal of Manufacturing Processes, 33, 86-95.
  • García-Moreno, F. (2016). Commercial applications of metal foams: Their properties and production. Materials, 9(2), 85.
  • Haferkamp, H., Bunte, J., Herzog, D., & Ostendorf, A. (2004). Laser based welding of cellular aluminium. Science and technology of welding and joining, 9(1), 65-71.
  • Hokamoto, K., Vesenjak, M., & Ren, Z. (2014). Fabrication of cylindrical uni-directional porous metal with explosive compaction. Materials Letters, 137, 323-327.
  • Ishizaki, K., Komarneni, S., & Nanko, M. (2013). Porous Materials: Process technology and applications (Vol. 4). Springer science & business media.
  • Kitazono, K., Kitajima, A., Sato, E., Matsushita, J., & Kuribayashi, K. (2002). Solid-state diffusion bonding of closed-cell aluminum foams. Materials Science and Engineering: A, 327(2), 128-132.
  • Longerich, S., Piontek, D., Ohse, P., Harms, A., Dilthey, U., Angel, S., & Bleck, W. (2007). Joining strategies for open porous metallic foams on iron and nickel base materials. Advanced Engineering Materials, 9(8), 670-678.
  • Metschkow, B. (2006). Sandwich panels in shipbuilding. Polish Maritime Research, 5-8.
  • Młynarczyk, P., & Depczyński, W. (2014). The selected properties of fusion of Fe foam and sheet metal with use of the Nd: YAG laser. Journal of Achievements in Materials and Manufacturing Engineering, 65(2), 68-72.
  • Murakami, T., Nakata, K., Ikeda, T., Nakajima, H., & Ushio, M. (2003). Weld fusion property of lotus-type porous copper by laser beam irradiation. Materials Science and Engineering: A, 357(1-2), 134-140.
  • Murakami, T., Tsumura, T., Ikeda, T., Nakajima, H., & Nakata, K. (2007). Anisotropic fusion profile and joint strength of lotus-type porous magnesium by laser welding. Materials Science and Engineering: A, 456(1-2), 278-285.
  • Nowacki, J., & Moraniec, K. (2015). Welding of metallic AlSi foams and AlSi–SiC composite foams. Archives of Civil and Mechanical Engineering, 15(4), 940-950.
  • Reisgen, U., Olschok, S., & Longerich, S. (2010). Laser beam welding of open-porous metallic foams for application in cooling structures of combined cycle power plants. Journal of engineering for gas turbines and power, 132(5).
  • Schwingel, D. D., Seeliger, D. H. W., Vecchionacci, M. C., Alwes, M. D., & Dittrich, M. J. (2007). Aluminium foam sandwich structures for space applications. In 57th International Astronautical Congress (pp. C2-4).
  • Seeliger, H. W. (2002). Manufacture of aluminum foam sandwich (AFS) components. Advanced engineering materials, 4(10), 753-758.
  • Selcuk, C. Bond S. & Woollin P. (2013). Joining Processes for Powder Metallurgy Parts. Advances in Powder Metallurgy, 380-398.
  • Sharma, V. M., Pal, S. K., & Racherla, V. (2020). A new sintering method for fabrication of open-cell metal foam parts. Materials and Manufacturing Processes, 35(15), 1717-1726.
  • Shih, J. S., Tzeng, Y. F., & Yang, J. B. (2011). Principal component analysis for multiple quality characteristics optimization of metal inert gas welding aluminum foam plate. Materials & Design, 32(3), 1253-1261.
  • Shirzadi, A. A., Kocak, M., & Wallach, E. R. (2004). Joining stainless steel metal foams. Science and technology of welding and joining, 9(3), 277-279.
  • Smith, B. H., Szyniszewski, S., Hajjar, J. F., Schafer, B. W., & Arwade, S. R. (2012). Steel foam for structures: A review of applications, manufacturing and material properties. Journal of Constructional Steel Research, 71, 1-10.
  • Su, X., Huang, P., Feng, Z., Gao, Q., Wei, Z., Sun, X., Zu, G., & Mu, Y. (2021). Study on aluminum foam sandwich welding by friction stir welding technology, Materials Letters, 304, 130605.
  • Vural, M. (2014) Welding processes and Technologies,S. Hashmi (Ed.), Comprehensive Materials Processing, Vol. 6, Elsevier, pp. 3-48. https://doi.org/10.1016/B978-0-08-096532-1.00603-8
  • Yao, C., Hu, Z., Mo, F., & Wang, Y. (2019). Fabrication and Fatigue Behavior of Aluminum Foam Sandwich Panel via Liquid Diffusion Welding Method. Metals, 9(5), 582.
Year 2022, Volume: 15 Issue: 1, 217 - 232, 27.03.2022
https://doi.org/10.18185/erzifbed.997743

Abstract

References

  • Ashby, M. F., Evans, T., Fleck, N. A., Hutchinson, J. W., Wadley, H. N. G., and Gibson, L. J. (2000). “Metal foams: a design guide”, Elsevier.
  • Banhart, J. 2001. “Manufacture, characterisation and application of cellular metals and metal foams”, Progress in materials science, 46(6), 559-632.
  • Banhart, J. 2005. “Aluminium foams for lighter vehicles”. International Journal of vehicle design, 37(2-3), 114-125.
  • Banhart, J., and Seeliger, H. W. 2007. “Aluminium foam sandwich panels: metallurgy, manufacture and applications”. In 5th Biennial International Conference on Porous Metals and Metallic Foams (MetFoam 2007).
  • Banhart, J., and Seeliger, H. W. 2008. “Aluminium foam sandwich panels: manufacture, metallurgy and applications”, Advanced Engineering Materials, 10(9), 793-802.
  • Banhart, J., Seeliger, W., & Beichelt, C. (2002). Sandwich Panels, Handbook of Cellular Metals Production, Processing, Applications, 113-125.
  • Born, C., Kuckert, H., Wagner, G., & Eifler, D. (2003). Ultrasonic torsion welding of sheet metals to cellular metallic materials. Advanced Engineering Materials, 5(11), 779-786.
  • Born, C., Wagner, G., & Eifler, D. (2006). Ultrasonically welded aluminium foams/sheet metal–joints. Advanced Engineering Materials, 8(9), 816-820.
  • Burzer, J., Bernard, T., & Bergmann, H. W. (1998). Joining of aluminium structures with aluminium foams. In MATERIALS RESEARCH SOCIETY SYMPOSIUM PROCEEDINGS (Vol. 521, pp. 159-164). MATERIALS RESEARCH SOCIETY.
  • Bušić, M., Kožuh, Z., Klobčar, D., & Samardžić, I. (2016). Friction stir welding (FSW) of aluminium foam sandwich panels. Metalurgija, 55(3), 473-476.
  • Changdar, A., & Chakraborty, S. S. (2021). Laser processing of metal foam-A review. Journal of Manufacturing Processes, 61, 208-225.
  • Feng, M. N., Xie, Y., Zhao, C. F., & Luo, Z. (2018). Microstructure and mechanical performance of ultrasonic spot welded open-cell Cu foam/Al joint. Journal of Manufacturing Processes, 33, 86-95.
  • García-Moreno, F. (2016). Commercial applications of metal foams: Their properties and production. Materials, 9(2), 85.
  • Haferkamp, H., Bunte, J., Herzog, D., & Ostendorf, A. (2004). Laser based welding of cellular aluminium. Science and technology of welding and joining, 9(1), 65-71.
  • Hokamoto, K., Vesenjak, M., & Ren, Z. (2014). Fabrication of cylindrical uni-directional porous metal with explosive compaction. Materials Letters, 137, 323-327.
  • Ishizaki, K., Komarneni, S., & Nanko, M. (2013). Porous Materials: Process technology and applications (Vol. 4). Springer science & business media.
  • Kitazono, K., Kitajima, A., Sato, E., Matsushita, J., & Kuribayashi, K. (2002). Solid-state diffusion bonding of closed-cell aluminum foams. Materials Science and Engineering: A, 327(2), 128-132.
  • Longerich, S., Piontek, D., Ohse, P., Harms, A., Dilthey, U., Angel, S., & Bleck, W. (2007). Joining strategies for open porous metallic foams on iron and nickel base materials. Advanced Engineering Materials, 9(8), 670-678.
  • Metschkow, B. (2006). Sandwich panels in shipbuilding. Polish Maritime Research, 5-8.
  • Młynarczyk, P., & Depczyński, W. (2014). The selected properties of fusion of Fe foam and sheet metal with use of the Nd: YAG laser. Journal of Achievements in Materials and Manufacturing Engineering, 65(2), 68-72.
  • Murakami, T., Nakata, K., Ikeda, T., Nakajima, H., & Ushio, M. (2003). Weld fusion property of lotus-type porous copper by laser beam irradiation. Materials Science and Engineering: A, 357(1-2), 134-140.
  • Murakami, T., Tsumura, T., Ikeda, T., Nakajima, H., & Nakata, K. (2007). Anisotropic fusion profile and joint strength of lotus-type porous magnesium by laser welding. Materials Science and Engineering: A, 456(1-2), 278-285.
  • Nowacki, J., & Moraniec, K. (2015). Welding of metallic AlSi foams and AlSi–SiC composite foams. Archives of Civil and Mechanical Engineering, 15(4), 940-950.
  • Reisgen, U., Olschok, S., & Longerich, S. (2010). Laser beam welding of open-porous metallic foams for application in cooling structures of combined cycle power plants. Journal of engineering for gas turbines and power, 132(5).
  • Schwingel, D. D., Seeliger, D. H. W., Vecchionacci, M. C., Alwes, M. D., & Dittrich, M. J. (2007). Aluminium foam sandwich structures for space applications. In 57th International Astronautical Congress (pp. C2-4).
  • Seeliger, H. W. (2002). Manufacture of aluminum foam sandwich (AFS) components. Advanced engineering materials, 4(10), 753-758.
  • Selcuk, C. Bond S. & Woollin P. (2013). Joining Processes for Powder Metallurgy Parts. Advances in Powder Metallurgy, 380-398.
  • Sharma, V. M., Pal, S. K., & Racherla, V. (2020). A new sintering method for fabrication of open-cell metal foam parts. Materials and Manufacturing Processes, 35(15), 1717-1726.
  • Shih, J. S., Tzeng, Y. F., & Yang, J. B. (2011). Principal component analysis for multiple quality characteristics optimization of metal inert gas welding aluminum foam plate. Materials & Design, 32(3), 1253-1261.
  • Shirzadi, A. A., Kocak, M., & Wallach, E. R. (2004). Joining stainless steel metal foams. Science and technology of welding and joining, 9(3), 277-279.
  • Smith, B. H., Szyniszewski, S., Hajjar, J. F., Schafer, B. W., & Arwade, S. R. (2012). Steel foam for structures: A review of applications, manufacturing and material properties. Journal of Constructional Steel Research, 71, 1-10.
  • Su, X., Huang, P., Feng, Z., Gao, Q., Wei, Z., Sun, X., Zu, G., & Mu, Y. (2021). Study on aluminum foam sandwich welding by friction stir welding technology, Materials Letters, 304, 130605.
  • Vural, M. (2014) Welding processes and Technologies,S. Hashmi (Ed.), Comprehensive Materials Processing, Vol. 6, Elsevier, pp. 3-48. https://doi.org/10.1016/B978-0-08-096532-1.00603-8
  • Yao, C., Hu, Z., Mo, F., & Wang, Y. (2019). Fabrication and Fatigue Behavior of Aluminum Foam Sandwich Panel via Liquid Diffusion Welding Method. Metals, 9(5), 582.
There are 34 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Makaleler
Authors

Gizem Karabulut 0000-0003-0930-5380

Nuray Beköz Üllen 0000-0003-2705-2559

Publication Date March 27, 2022
Published in Issue Year 2022 Volume: 15 Issue: 1

Cite

APA Karabulut, G., & Beköz Üllen, N. (2022). A Review on Welding Techniques of Metallic Foams. Erzincan University Journal of Science and Technology, 15(1), 217-232. https://doi.org/10.18185/erzifbed.997743