WO2016156186A1 - Procédé de fabrication d'éléments sandwich expansés - Google Patents

Procédé de fabrication d'éléments sandwich expansés Download PDF

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Publication number
WO2016156186A1
WO2016156186A1 PCT/EP2016/056508 EP2016056508W WO2016156186A1 WO 2016156186 A1 WO2016156186 A1 WO 2016156186A1 EP 2016056508 W EP2016056508 W EP 2016056508W WO 2016156186 A1 WO2016156186 A1 WO 2016156186A1
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WO
WIPO (PCT)
Prior art keywords
foaming
foamed
metallic
extrusion
foamable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2016/056508
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German (de)
English (en)
Inventor
Jörg HOHLFELD
Christian Hannemann
Patrick BERTHOLD
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fraunhofer Gesellschaft zur Foerderung der Angewandten Forschung eV
Original Assignee
Fraunhofer Gesellschaft zur Foerderung der Angewandten Forschung eV
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Filing date
Publication date
Application filed by Fraunhofer Gesellschaft zur Foerderung der Angewandten Forschung eV filed Critical Fraunhofer Gesellschaft zur Foerderung der Angewandten Forschung eV
Publication of WO2016156186A1 publication Critical patent/WO2016156186A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/08—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of metal, e.g. sheet metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/04—Inorganic
    • B32B2266/045—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/206—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ

Definitions

  • the invention relates to a process for producing foamed sandwich elements and to a foamed sandwich element produced by means of such a process.
  • sandwich construction offers a high potential to achieve this goal.
  • materials with different properties are combined in several layers to form a sandwich element.
  • the properties of such sandwich elements can be individually adapted to the needs via various parameters, such as the material selection of the cover and core layers, the arrangement or order of these layers or the shape of the sandwich element.
  • Sandwich elements are used for some time as lightweight components for different applications and often replace high-strength materials such as metallic materials u. Like., And their potential exceed both in terms of strength and rigidity and the energy absorption capacity and damping.
  • the production of sandwich panels today is largely by gluing layers of core and cover material, which are each made separately from each other.
  • the disadvantage of this manufacturing method and the resulting sandwich elements, however, is that the adhesive surface between the core and cover material is a weak point, which affects the mechanical properties of the sandwich element.
  • metal foam as a core material in conjunction with solid sheet cover layers for load bearing, distribution and transfer.
  • the connection of the metal foam to the cover plates is formed by a - realized during the foaming - deadline.
  • advantageously no adhesive is necessary and the risk of delamination caused by heat, cold, corrosion, chemicals or other influences decreases.
  • aluminum foam as a core layer, the alloy may vary depending on the application.
  • the cover sheets are usually made of steel or aluminum or aluminum alloys.
  • a foamable, metallic material usually takes place by homogeneous mixing of a metal powder with a propellant powder (eg titanium hydride) and by subsequent compaction and optionally shaping (eg extrusion, rolling) to a foamable starting material.
  • a propellant powder eg titanium hydride
  • the blowing agent releases a gas (eg hydrogen) when heated.
  • a gas eg hydrogen
  • the metal foam is cooled when reaching the maximum foam expansion below the solidus temperature of the metal and thus transferred to the solid phase.
  • the challenge is to introduce the amount of heat required for foaming through the cover layer into the foamable core layer without, however, melting the cover layer.
  • the prepared composite is usually foamed in a convection oven which can be heated to a foaming temperature.
  • the foaming temperature is in the sense of rapid process control about 10 to 150 K above the solidus temperature of the foamable metal (ie in the case of aluminum between about 580 and 810 ° C). Even at these high temperatures steel cover sheets remain largely stable, d. H. they do not melt.
  • the sandwich production is relatively unproblematic in this case.
  • cover sheets melt at least in a similar temperature range as the foamable core material.
  • the material selection is based on a higher-melting aluminum alloy (eg AlMg I Si) or even on pure aluminum, whereas a low-melting alloy variant (eg AISi 12) is used for the core layer. If, in addition, it is possible to create a positive and / or cohesive bond in advance between the foamable core layer and the cover plates, the heat transfer through the cover plate into the foamable material is significantly accelerated and the foaming process can be completed before the cover plates melt.
  • a higher-melting aluminum alloy eg AlMg I Si
  • a low-melting alloy variant eg AISi 12
  • a method and an apparatus for the production of foamed bodies in a foaming mold are disclosed in DE 10 2005 020 036 B3.
  • a cover plate is first inserted into the foaming mold, onto which the foamable material (produced, for example, by extrusion or rolling) is subsequently deposited, which in turn is finally closed off by another cover plate.
  • the heat treatment of the above-described composite for foaming of the core material takes place.
  • the upper cover plate is raised with progressing foam front until it abuts on the upper mold wall.
  • the upper cover plate can also be positioned and held in a fixed position above the foamable material, thereby eliminating the risk of tipping up of the upper cover plate. In any case, account must be taken of that the cover sheets expand when heated.
  • DE 10 2007 006 156 B3 and DE 10 2012 005 090 B3 each disclose processes for producing profile-like composites in the extrusion process by jointly pressing a solid metal tube with an inserted block of foamable metal.
  • a foamable metal block is placed in a solid metal tube almost filling the mold in a solid metal tube.
  • a profile with a solid outer skin and a foamable inner layer is produced.
  • the foaming of the inner layer takes place in order to achieve a partial or complete foaming of the profile cavity.
  • the invention has for its object to provide a method for producing a foamed sandwich element that is simple and therefore economically applicable even for small quantities while still meeting high quality requirements.
  • a method for producing foamed sandwich elements comprising the following steps: a) providing a cross-sectionally closed sleeve of a metallic cover material, b) filling the sleeve interior with a foamable, metallic core material, c) extruding the padded Sleeve to an extruded profile with a metallic cover layer and a foamable, metallic core layer, d) foaming the extruded profile to a foamed sandwich element with at least one metallic cover layer and a foamed core layer.
  • an extrusion process is used.
  • An extrusion process is much easier to perform than a rolling process.
  • the minimum production quantities for extrusion are significantly lower than for rolling. This means that cost-effective production is also possible for small batches (a few tonnes).
  • the heat transfer between the covering material and the foamable core material is optimized in the subsequent foaming in such a way that no significant temperature gradients can occur between the two materials. Due to the higher melting interval of the cover material compared to the core material and the good heat transfer, the melting of the cover material is avoided.
  • the cover layers thus show no change in shape or molten areas.
  • a high heating rate for the foamable core material is achieved, whereby a good pore morphology and a homogeneous density distribution in the foam core can be achieved.
  • the sleeve provided in step a) or the sleeve filled in step b) is annealed prior to the extrusion according to step c) and / or preheated to the extrusion temperature.
  • the subsequent extrusion can be facilitated.
  • the selected annealing temperature and extrusion temperature depend in each case on the alloy compositions of the cover and core material.
  • the metallic cover layer along the opposite narrow sides of the extruded profile is removed before foaming according to step d).
  • step d) before the foaming according to step d), in particular during the extrusion according to step c), along the opposite narrow sides of the extruded profile in each case a predetermined breaking line in the metallic cover layer of the extruded profile introduced by the during foaming According to step d) acting foaming pressure to form a foamed sandwich element with two cover layers and a foamed core layer is broken.
  • rupture lines also aim to weaken the side walls of the cover layers obstructing foam expansion in the vertical direction and to allow them to rupture during the foaming process.
  • a high-quality sandwich element can be produced, which consists of two solid cover layers and a core foam layer with maximum expansion height.
  • the predetermined breaking line can be generated by a notch introduced into the surface of the cover layer. The formation of the notch preferably takes place simultaneously in time to the extrusion process, z. B. by a laterally acting on the profile, integrated in the extrusion tool Ein josgewerkmaschine. In this way, one or more indentations can be produced inexpensively without additional work steps.
  • one or more indentations can be introduced into the extruded profile before foaming in accordance with step d), in particular during the extrusion according to step c), which by the foaming pressure acting on foaming according to step d) to form a sandwich element with a closed cover layer and a foamed core layer are smoothed again.
  • a special shaping of the foamable semifinished product can also be used to produce foamed pipes and profiles (eg rectangular profiles).
  • the circumference of the extruded, foamable profile should already correspond to the extent of the later, foamed profile, since the solid edge (the top layer) of the foamable profile is not stretched during the foaming process, but only formed.
  • the previously introduced indentations are pushed back outward by the internal pressure (foaming pressure) produced in the closed cross-section during foaming in order to obtain the desired, foamed cross-sectional shape (circular, rectangular ).
  • engagement and counter-engagement elements can be introduced into the cover layer of the extruded profile, by means of which several extruded profiles or, after foaming in accordance with step d), several foamed sandwich elements with each other before foaming according to step d) - And / or frictionally engaged.
  • snap or click elements can be provided.
  • the extruded profiles or foamed sandwich elements z. B. by means of a "click" system (similar to laminate) side by side by a mechanical connection of high strength are engaged with each other.
  • FIG. 2 shows a foamable, extruded profile and a sandwich element foamed therefrom according to a second exemplary embodiment of the method according to the invention
  • FIG. 3 shows a foamable, extruded profile and a sandwich element foamed therefrom according to a third exemplary embodiment of the method according to the invention
  • FIG. 4 shows a foamable, extruded profile and a sandwich element foamed therefrom according to a fourth exemplary embodiment of the method according to the invention
  • Fig. 5 is a foamable, extruded profile and a foamed sandwich element according to a fifth embodiment of the method according to the invention.
  • Fig. 1 the four temporally successive process steps a) to d) of the process according to the invention are shown with reference to the intermediate or end products respectively obtained at the end of these process steps a) to d).
  • these intermediate and end products are respectively to be seen in longitudinal section views, whereas in the lower half of the drawing these intermediate and end products are each shown in cross-sectional views.
  • a sleeve 2 in the form of a thick-walled tube of pure aluminum or an aluminum alloy is provided, which is the covering material 3 of the later cover layers 10a, 10b of the sandwich element 1 forms.
  • Such an aluminum tube may have been manufactured in a conventional manner by pressing and / or rolling and / or drawing.
  • the outer dimensions are to be selected so that the sleeve 2 in the subsequent method step c) fits into the recipients of the extrusion die provided for the extrusion process.
  • the wall thickness of the sleeve, the cross-section of the extrusion recipient and the forming behavior in the extrusion die determine the later ratio of the cover layer to the foamed core layer.
  • a foamable metallic core material 5 is a mixture of aluminum powder or aluminum swarf with a blowing agent.
  • the blowing agent decomposes to form a propellant gas, which causes the foaming of the high-viscosity aluminum melt to form a foamed core layer 11.
  • the foamable metal powder or metal chip mixture should be filled into the sleeve 2 with a high degree of compaction.
  • the compaction of the mixture takes place for example by means of uniaxial compaction or by extrusion.
  • the extruded or otherwise compacted core material 5 is placed almost form filling in the solid sleeve 2.
  • sleeve 6 are subjected to a soft annealing.
  • the still unfilled sleeve 2 can be annealed before filling, ie between the process steps a) and b).
  • Soft annealing which is also referred to as recrystallization annealing, is a heat treatment at an annealing temperature just below the lower transformation point. After holding this annealing temperature for several hours, a slow cooling takes place. As a result, a soft microstructure is obtained in the treated sleeve 6, which enables easier processability in the subsequent extrusion process.
  • the filled-in and soft-annealed sleeve 6 is then preheated (eg, inductively) to the extrusion temperature and introduced into the recipient of the extruder.
  • an extruded profile 7 with the cross-section shown in view c1) of FIG. 1 is produced from the sleeve 6.
  • the extruded profile 7 comprises within a closed senen rectangular cover layer 8 (from a higher melting pure aluminum or an aluminum alloy) a frothable rectangular core layer 9 (from a mixed with blowing agent low-melting aluminum alloy).
  • the process parameters suitable for the respective alloy such as extrusion temperature, ratio and speed
  • extrusion temperature, ratio and speed are set in such a way that the forming result desired for the subsequent foaming process is obtained.
  • the extrusion allows the production of a strand whose length can range from a few meters to over 100 meters.
  • the cover layer 8 is removed along the narrow sides 12a, 12b of the extruded profile 7 (ie along the flat edge regions, which have an edge height of 10 mm according to the aforementioned example).
  • This separating process also referred to as "trimming" is illustrated in FIG. 1 as a sub-process step for process step c) by the transition from view c1) to view c2).
  • the trimming of the extruded profiles 7 can be done immediately after the extrusion process, d. H. inline with the extrusion process.
  • the extruded profiles can be longitudinally fed to a sawing device via a conveying path designed as a roller conveyor. However, trimming can also take place in a separate process step.
  • the non-foamable cover layer 8 obstructing the subsequent foaming process is removed on the narrow sides 12a, 12b of the extruded profile 7.
  • a maximum foam expansion of the core layer 9 in the vertical direction i. H. in the direction of the two remaining on the profile 7 upper and lower outer layers, done.
  • the maximum expansion of the core layer 11 gives a high quality sandwich element with excellent strength, sound absorption and energy absorption capabilities.
  • the indentations 13a, 13b are each extended to the outside of the profile 7 toward V-shaped and extend in the extrusion direction along the entire length of the profile 7. They each form a predetermined breaking line during the subsequent foaming process according to step d) as a result of the foam expansion forming foaming pressure ruptures. This results in a sandwich element 1 with two separate (upper and lower) cover layers 10a, 10b, between which a high-quality, maximally expanded metal foam core layer 1 1 is arranged.
  • the indentations 13a, 13b can be introduced in an economical manner quickly and without any special effort by means of a corresponding embossing tool integrated in the extrusion tool or directly downstream of the extrusion tool.
  • the cover layer 8 shown in FIGS. 1 to 3 instead of the trimming or weaknesses of the cover layer 8 shown in FIGS. 1 to 3 according to the embodiments shown in FIGS. 4 and 5, it is also possible, by a corresponding shaping of the extruded profile 7, to produce a foamed sandwich element 1 with a closed circumferential solid cover layer 10 realize.
  • the circumference of the extruded foamable profile 7 should already correspond to the extent of the later foamed profile 1, since the massive edge of the foamable semifinished product can not be stretched in the foaming process, but can only be formed.
  • the production of a sandwich element 1 in the form of a rectangular profile is made possible by a special shaping of the foamable semifinished product.
  • a lateral indentation 14a, 14b in the form of a concave depression is introduced in the opposite narrow sides 12a, 12b of the foamable profile 7.
  • this two-sided depression 14a, 14b is again pressed horizontally outwards in each case, and in each case a smooth, vertically extending side wall of the rectangular profile is formed.
  • an approximately triangular depression 14a, 14b is formed in the opposite broad sides 16a, 16b of the foamable profile 7.
  • This bilateral recess 14a, 14b is pressed vertically upwards or downwards again by the all-round foaming pressure during the subsequent foaming process, so that after completion of the foaming process, a recess-free circular-cylindrical cross-section is established.
  • a sandwich element 1 a tubular profile is obtained with a foamed, cylindrical core layer 11, which is of solid, annular shape Cover layer 10 is surrounded.
  • extruded profiles 7 and / or the sandwich elements 11 produced therefrom can be joined by welding processes (eg TIG, laser, friction stir welding) to form large, rigid constructions or platforms.
  • welding processes eg TIG, laser, friction stir welding
  • additional overlay pockets 15a and joining slots 15b cooperating therewith can be formed on or molded into opposite broad sides 16a, 16b.
  • a plurality of extruded profiles 7 or foamed sandwich elements 1 can be brought next to one another in a form-fitting engagement with one another over a large area via a secure and error-free connection.
  • non-positive engagement and counter-engagement elements can be formed in the cover layer 8 of the extruded profile 7.
  • 15b and clinker joints 15b may advantageously be provided additional clawing elements, over which several extruded profiles 7 or foamed sandwich elements 1 (similar to a "click" system used in laminates) to form a sheet-like construction or platform positively and non-positively assembled are.
  • the extruded profile 7 provided with a trimmed, weakened or deformed edge-more efficiently by utilizing the residual heat-is foamed immediately after the extrusion process.
  • a foaming mold or a foaming mold is expedient, but not a condition.
  • the metallic covering material 3 used (pure metal or alloy) has a higher melting point than the metallic component contained in the core material 5.
  • the extrusion process is much easier than the rolling process.
  • the minimum production quantities are significantly lower for extrusion than for rolling.
  • the method according to the invention opens up the possibility for the first time of realizing cost-effective production even of small batches (a few tonnes) of foamed sandwich elements 1. Since it is possible to manufacture foamed sandwich elements 1 from extruded semi-finished products more cost-effectively, the market penetration of such sandwich elements 1 is made considerably easier. Conventional, by foaming However, products made from rolled composites often have an unacceptable price, especially for smaller quantities.
  • a sandwich element 1 produced according to the invention by extrusion and subsequent foaming has a different grain structure than a sandwich element produced conventionally by foaming of rolled semi-finished products. From a transverse section it can be seen that the grain structure of the sandwich element produced on the basis of a rolled material shows a longitudinal flattened shape of the grains, whereas the sandwich element 1 produced according to the invention on the basis of an extruded material also has longitudinal, but at right angles thereto a uniform grain structure.
  • the sandwich element 1 produced according to the invention has a grain aspect ratio of X / Y -1, while Conventionally (by rolling) sandwich element produced a grain aspect ratio X / Y ⁇ 1 applies.
  • the sandwich element 1 according to the invention which has been prepared by extrusion and subsequent foaming, can be used in all areas in which light construction with simultaneously high flexural strength and / or high vibration damping capacity and / or high energy absorption capacity is important.
  • the fields of application include mechanical engineering, machine tool construction, shipbuilding, rail vehicle construction, commercial vehicle construction, construction, automotive engineering, process engineering or packaging.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé de fabrication d'éléments sandwich expansés. L'invention concerne un procédé de fabrication d'éléments sandwich expansés comprenant les quatre étapes de procédé fondamentales suivantes : a) la fourniture d'un manchon fermé en section transversale et fait d'un matériau de recouvrement métallique, b) le remplissage de l'intérieur du manchon avec un matériau central métallique pouvant être expansé, c) l'extrusion du manchon rempli de manière à obtenir un profilé extrudé présentant une couche de couverture métallique et une couche centrale métallique pouvant être expansée, d) l'expansion du profilé extrudé de manière à obtenir un élément sandwich expansé présentant au moins une couche de couverture métallique et une couche centrale expansée. Un procédé de ce type permet de fabriquer des éléments sandwich expansés (y compris en cas de faibles charges) d'une manière peu onéreuse, mais d'excellente qualité.
PCT/EP2016/056508 2015-03-31 2016-03-24 Procédé de fabrication d'éléments sandwich expansés Ceased WO2016156186A1 (fr)

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DE102015205829.8A DE102015205829B4 (de) 2015-03-31 2015-03-31 Verfahren zur Herstellung von geschäumten Sandwichelementen
DE102015205829.8 2015-03-31

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DE102017207823B4 (de) * 2017-05-09 2020-02-20 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zum Herstellen eines aufschäumbaren Halbzeugs
CN111482606A (zh) * 2020-06-09 2020-08-04 浦江吉树机械科技有限公司 一种泡沫金属的挤压调节装置
DE102024108745A1 (de) * 2024-03-27 2025-10-02 HAVEL metal foam GmbH Verfahren zur Herstellung eines Metallschaumprodukts aus einem aluminiumhaltigen Werkstoff mithilfe einer abschnittsweise mit einem Trennmittel beschichteten Werkzeugform sowie Werkzeugform

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EP1000690A2 (fr) 1998-11-13 2000-05-17 Schunk Sintermetalltechnik Gmbh Procédé de préparation d'un produit semi-fini moussable ainsi que d un produit semi-fini
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