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Aerogel Filled Metals: a Syntactic Cellular Material

Orth, Andreas and Steinbach, Sonja and Ratke, Lorenz (2012) Aerogel Filled Metals: a Syntactic Cellular Material. CELLMAT 2012, 7.11. - 9.11. 2012, Dresden.

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Abstract

We report in this paper on a new method to produce lightweight aluminium alloys introducing nanostructured materials like silica-aerogels into an Al-alloy melt. Since these filler materials in the range of a few 100 micron to a few millimetres have vanishing density (100g/L) they need not to be removed from the final cast product. Their shape, size and volume fraction determines the materials properties. Different methods were used to prepare metal-aerogel syntactic foam composites. Filling of aerogel particles into a mould and using centrifugal casting to backfill the void space between the silica-aerogel particles is one way to produce such a material. This process was employed to prepare samples using Silica aerogels and an A357 alloy. Vermiculites and Hyperlite as a filler materials. The materials have densities around 1000g/L, compressive yields stress of around 10-20 MPa with maximum compressibility of around 60%. Another method is an inverse squeeze casting process. The aerogel granulate bed is preheated and slowly pressed into a superheated AlSi11 melt. The composite material typically has a density of around 900 g/L, compressive yields stress of around 8 MPa and the energy absorption at a deformation of 40% is around 8kJ/kg. In a third processing routine we employed a kind of suction casting (or inverse low pressure die casting). A tube filled with millimetre sized Silica-aerogel particles is evacuated, preheated and submerged partially into an AlSi11 melt. The melt penetrates into the void space and composite materials up to 500 mm length can be produced. The paper describes the materials preparation methods, the microstructures as observed with light microscopy and X-ray tomography, the deformation behaviour and discusses the different techniques and their advantages and limitations.

Document Type:Conference or Workshop Item (Speech)
Title:Aerogel Filled Metals: a Syntactic Cellular Material
Authors:
AuthorsInstitution or Email of Authors
Orth, AndreasUNSPECIFIED
Steinbach, SonjaUNSPECIFIED
Ratke, LorenzUNSPECIFIED
Date:November 2012
Keywords:Aerogels, cellular metals, suction csting, squeeze casting
Event Title:CELLMAT 2012
Event Location:Dresden
Event Type:international Conference
Event Dates:7.11. - 9.11. 2012
Organizer:DGM
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Terrestrial Vehicles
DLR - Research area:Transport
DLR - Program:V BF - Bodengebundene Fahrzeuge
DLR - Research theme (Project):V - Neuartige Fahrzeugstrukturen (old)
Location: Köln-Porz
Institutes and Institutions:Institute of Materials Physics in Space
Deposited By: Prof. Lorenz Ratke
Deposited On:14 Nov 2012 13:40
Last Modified:14 Nov 2012 13:40

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