journal article·2023-08Open access

Effect of cell size on the response to solution and aging heat treatments of open-cell Al-4.5Cu (wt.%) foams

Manuel F. Azamar, Brenda J. Hernández, Ignacio A. Figueroa, Ricardo Hernández, Gonzalo González, Omar Novelo-Peralta, Ismeli Alfonso

Journal of Materials Science· Volume 58· Issue 29

Abstract

Abstract Open-cell Al-4.5Cu (wt.%) foams were produced by the replication casting technique in cell sizes of 2.00–2.38 and 3.35–4.75 mm. The fabricated foams were subjected to solution and aging treatments to assess the effect of such heat treatments on the microstructure and mechanical properties of the foams as a function of cell size. Solution and aging heat treatments were carried out at 535 °C for 5.5 h and 170 °C for 8 h, respectively. The porosity and relative density of all produced samples were estimated by He pycnometer. In addition, the average cell wall thickness was assessed by image analysis to correlate this variable with the response to heat treatments of the material. The microstructural evolution of the heat-treated samples was analyzed by means of scanning electron microscopy, scanning transmission electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and differential scanning calorimetry. The mechanical characterization of the studied samples was carried out using uniaxial compression tests and microhardness tests. It was found that the foams did present different responses to both solution and aging treatments as a function of cell size, attributing these outcomes to the cell wall thickness variations, which presumably conditioned the cooling rates after heat treatments, thereby influencing the resulting microstructures and precipitation of Al-Cu second phases. Graphical abstract
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Cellular and Composite Structures · Aluminum Alloys Composites Properties · Aluminum Alloy Microstructure Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (52)

Show source-provided references
1. Gibson LJ, Ashby MF (1999) Cellular solids: structure and properties, 2nd edn. Cambridge University Press, Cambridge
2. García-Moreno F (2016) Commercial applications of metal foams: their properties and production. Materials 9:85–111. https://doi.org/10.3390/ma902008510.3390/ma9020085 ↗
3. Lefebvre LP, Banhart J, Dunand DC (2008) Porous metals and metallic foams: current status and recent developments. Adv Eng Mater 10(9):775–787. https://doi.org/10.1002/adem.20080024110.1002/adem.200800241 ↗
4. Banhart J (2001) Manufacture, characterisation and application of cellular metals and metal foams. Prog Mater Sci 46:559–632. https://doi.org/10.1016/S0079-6425(00)00002-510.1016/S0079-6425(00)00002-5 ↗
5. Banhart J (2000) Manufacturing routes for metallic foams. JOM 52:22–27. https://doi.org/10.1007/s11837-000-0062-810.1007/s11837-000-0062-8 ↗
6. Aghion E, Perez Y (2014) Effects of porosity on corrosion resistance of Mg Alloy foam produced by powder metallurgy technology. Mater Charact 96:78–83. https://doi.org/10.1016/j.matchar.2014.07.01210.1016/j.matchar.2014.07.012 ↗
7. Trinidad J, Marco I, Arruebarrena G, Wendt J, Letzig D, Sáenz E, Goodall R (2014) Processing of magnesium porous structures by inflitration casting for biomedical applications. Adv Eng Mater 16(2):241–247. https://doi.org/10.1002/adem.20130023610.1002/adem.201300236 ↗
8. Elizondo-Luna EM, Barari F, Woolley R, Goodall R (2014) Casting protocols for the production of open cell aluminum foams by the replication tecnique and the effect on porosity. J Vis Exp 94:e52268. https://doi.org/10.3791/5226810.3791/52268 ↗
9. Osorio-Hernandez JO, Suarez MA, Goodall R, Lara-Rodriguez GA, Alfonso I, Figueroa IA (2014) Manufacturing of open-cell Mg foams by replication process and mechanical properties. Mater Des 64:136–141. https://doi.org/10.1016/j.matdes.2014.07.01510.1016/j.matdes.2014.07.015 ↗
10. Despois JF, Marmottant A, Salvo L, Mortensen A (2007) Influence of infiltration pressure on the structure and properties of replicated aluminium foams. Mater Sci Eng A 462:68–75. https://doi.org/10.1016/j.msea.2006.03.15710.1016/j.msea.2006.03.157 ↗
11. Yuan L, Yanxiang L, Jiang W (2007) Directional solidification of metal-gas eutectic and fabrication of regular porous metals. Front Mech Eng China 2(2):180–183. https://doi.org/10.1007/s11465-007-0030-x10.1007/s11465-007-0030-x ↗
12. Suarez MA, Figueroa IA, Gonzalez G, Lara-Rodriguez GA, Novelo-Peralta O, Alfonso I, Calvo IJ (2014) Production of Al-Cu-Fe metallic foams without foaming agents or space holders. J Alloys Compd 585:318–324. https://doi.org/10.1016/j.jallcom.2013.08.01510.1016/j.jallcom.2013.08.015 ↗
13. Hernández JM, Figueroa IA, González G, Salas AE, Mendoza LE, Alfonso I, Lara-Rodríguez GA (2022) In-situ porosity formation of self-foaming Al-Fe-Cu alloys. Appl Phys A Mater Sci Process 319:9. https://doi.org/10.1007/s00339-022-05454-810.1007/s00339-022-05454-8 ↗
14. Sun Y, Burgueño R, Vanderklok AJ, Tekalur SA (2014) Compressive behavior of aluminum-copper hybrid foams under high strain rate loading. Mater Sci Eng A 592:111–120. https://doi.org/10.1016/j.msea.2013.10.10410.1016/j.msea.2013.10.104 ↗
15. Wang H, Zhu DF, Hou S, Yang DH, Nieh TG, Lu ZP (2020) Cellular structure and energy absorption of Al-Cu alloy foams fabricated via a two-step foaming method. Mater Des 196:109090. https://doi.org/10.1016/j.matdes.2020.10909010.1016/j.matdes.2020.109090 ↗
16. Huang L, Wang H, Yang DH, Ye F, Wang SQ, Lu ZP (2014) Effects of Calcium on mechanical properties of cellular Al-Cu foams. Mater Sci Eng A 618:471–478. https://doi.org/10.1016/j.msea.2014.09.05110.1016/j.msea.2014.09.051 ↗
17. Lehmhus D, Banhart J (2003) Properties of heat-treated aluminium foams. Mater Sci Eng A 349:98–110. https://doi.org/10.1016/S0921-5093(02)00582-810.1016/S0921-5093(02)00582-8 ↗
18. Lehmhus D, Banhart J, Rodríguez-Perez MA (2002) Adaptation of aluminium foam properties by means of precipitation hardening. Mater Sci Technol 18:474–479. https://doi.org/10.1179/02670830222500218210.1179/026708302225002182 ↗
19. Campana F, Pilone D (2009) Effect of heat treatments on the mechanical behaviour of aluminium alloy foams. Scr Mater 60:679–682. https://doi.org/10.1016/j.scriptamat.2008.12.04510.1016/j.scriptamat.2008.12.045 ↗
20. Zhou J, Gao Z, Cuitino AM, Soboyejo WO (2004) Effects of heat treatment on the compressive deformation behavior of open cell aluminum foams. Mater Sci Eng A 386:118–128. https://doi.org/10.1016/j.msea.2004.07.04210.1016/j.msea.2004.07.042 ↗
21. Yamada Y, Shimojima K, Sakaguchi Y, Mabuchi M, Nakamura M, Asahina T, Mukai T, Kanahashi H, Higashi K (2000) Effects of heat treatment on compressive properties of AZ91 Mg and SG91A Al foams with open-cell structure. Mater Sci Eng A 280:225–228. https://doi.org/10.1016/S0921-5093(99)00671-110.1016/S0921-5093(99)00671-1 ↗
22. Cao X, Wang Z, Ma H, Zhao L, Yang G (2006) Effects of heat treatment on dynamic compressive properties and energy absorption characteristics of open-cell aluminum alloy foams. Trans Nonferrous Met Soc China 16:159–163. https://doi.org/10.1016/S1003-6326(06)60028-910.1016/S1003-6326(06)60028-9 ↗
23. Figueroa IA, Mendieta I, Azamar MF, Lara-Rodríguez GA, Novelo-Peralta O (2021) Mechanical behavior of heat-treated Al-Cu-Mg open-cell foams. Mater Lett 284:129021. https://doi.org/10.1016/j.matlet.2020.12902110.1016/j.matlet.2020.129021 ↗
24. Conde Y, Mortensen A (2008) Age-hardening response of replicated microcellular Al-4.5%Cu. Adv Eng Mater 10(9):849–852. https://doi.org/10.1002/adem.20080008610.1002/adem.200800086 ↗
25. Kaufman JG (2000) Introduction to aluminum alloys and tempers, first printing. ASM International, Materials Park, OH, USA
26. Thomas G, Whelan MJ (1961) Observations of precipitation in thin foils of aluminium + 4% copper alloy. Philos Mag 6(69):1103–1114. https://doi.org/10.1080/1478643610823967210.1080/14786436108239672 ↗
27. Martinez R, Guillot I, Massinon D (2019) New heat treatment to improve the mechanical properties of low copper aluminum primary foundry alloy. Mater Sci Eng A 755:158–165. https://doi.org/10.1016/j.msea.2019.04.00110.1016/j.msea.2019.04.001 ↗
28. Takeda M, Maeda Y, Yoshida A, Yabuta K, Konuma S, Endo T (1999) Discontinuity of GP(I) zone and θ’’-phase in an Al-Cu alloy. Scr Mater 41(6):643–649. https://doi.org/10.1016/S1359-6462(99)00137-210.1016/S1359-6462(99)00137-2 ↗
29. Starink MJ, van Mourik P (1992) Cooling and heating rate dependence of precipitation in an Al-Cu alloy. J Mater Sci Eng A 156:183–194. https://doi.org/10.1016/0921-5093(92)90150-Y10.1016/0921-5093(92)90150-Y ↗
30. Son SK, Takeda M, Mitome M, Bando Y, Endo T (2005) Precipitation behavior of an Al-Cu Alloy During isothermal aging at low temperatures. Mater Lett 59:629–632. https://doi.org/10.1016/j.matlet.2004.10.05810.1016/j.matlet.2004.10.058 ↗
31. C. San Marchi, A. Mortensen, Infiltration and the Replication Process for Producing Metal Sponges, in: H.P. Degischer, B. Kriszt (Eds.), Handbook of Cellular Metals: Production, Processing, Applications, Wiley-VCH, Weinheim, Germany, 2002, pp. 43–56.
32. Azamar MF, Figueroa IA, González G, Alfonso I (2021) Assessment of the flow behavior and structural performance of open-cell aluminum foams at critical flow conditions of pressure and temperature. J Mater Res. https://doi.org/10.1557/s43578-021-00382-410.1557/s43578-021-00382-4 ↗
33. Choi SW, Cho HS, Kumai S (2016) Effect of the precipitation of secondary phases on the thermal diffusivity and thermal conductivity of Al-45Cu alloy. J Alloys Compd 688:897–902. https://doi.org/10.1016/j.jallcom.2016.07.13710.1016/j.jallcom.2016.07.137 ↗
34. Conde Y, Mortensen A (2010) Solidification of Al-4.5 wt pct Cu-replicated foams. Metall Mater Trans A 41A:2048–2055. https://doi.org/10.1007/s11661-010-0297-010.1007/s11661-010-0297-0 ↗
35. Kurum EC, Dong HB, Hunt JD (2005) Microsegregation in Al-Cu alloys. Metall Mater Trans A 36A:3103–3110. https://doi.org/10.1007/s11661-005-0082-710.1007/s11661-005-0082-7 ↗
36. Chen T, Li X, Guo H, Hao Y (2015) Microstructure and crystal growth direction of Al−Cu alloy. Trans Nonferrous Met Soc China 25:1399–1409. https://doi.org/10.1016/S1003-6326(15)63739-610.1016/S1003-6326(15)63739-6 ↗
37. Azamar MF, Hernández BJ, Figueroa IA, González G, Novelo-Peralta O, Ramos CD (2021) Efect of the Cu addition on the mechanical properties and microstructure of open-cell Al foams. J Mater Res 36:3194–3202. https://doi.org/10.1557/s43578-021-00351-x10.1557/s43578-021-00351-x ↗
38. Smallman RE, Ngan AH (2014) Modern physical metallurgy, 8th edn. Butterworth-Heinemann, Waltham
39. Salanne M, Marrocchelli D, Merlet C, Ohtori N, Madden PA (2011) Thermal conductivity of ionic systems from equilibrium molecular dynamics. J Phys Condens Matter 23:10210110.1088/0953-8984/23/10/102101 ↗
40. Mahathaninwong N, Plookphol T, Wannasin J, Wisutmethangoon S (2012) T6 heat treatment of rheocasting 7075 Al alloy. Mater Sci Eng A 532:91–99. https://doi.org/10.1016/j.msea.2011.10.06810.1016/j.msea.2011.10.068 ↗
41. Avner SH (1974) Introduction to physical metallurgy, 2nd edn. McGraw-Hill, Singapore
42. Draissia M, Debili M-Y (2005) Study of solid-solution hardening in binary aluminium-based alloys. Cent Eur J Phys 3:395–408. https://doi.org/10.2478/BF0247564610.2478/BF02475646 ↗
43. Starink MJ, Dion A (2004) DSC study of precipitation in an Al–Mg–Mn alloy microalloyed with Cu. Thermochim Acta 417:5–11. https://doi.org/10.1016/j.tca.2004.01.01310.1016/j.tca.2004.01.013 ↗
44. Sajadifar SV, Krooß P, Fröck H, Milkereit B, Kessler O, Niendorf T (2021) Effects of aging under stress on mechanical properties and microstructure of EN AW 7075 alloy. Metals 11:1142. https://doi.org/10.3390/met1107114210.3390/met11071142 ↗
45. Rodríguez-Veiga A, Bellón B, Papadimitriou I, Esteban-Manzanares G, Sabirov I, Llorca J (2018) A multidisciplinary approach to study precipitation kinetics and hardening in an Al-4Cu (wt.%) alloy. J Alloys Compd 757:504–519. https://doi.org/10.1016/j.jallcom.2018.04.28410.1016/j.jallcom.2018.04.284 ↗
46. Benali A, Lacaze-Dufaure C, Morillo J (2011) Density functional study of copper segregation in aluminum. Surf Sci 605:341–350. https://doi.org/10.1016/j.susc.2010.10.04010.1016/j.susc.2010.10.040 ↗
47. Shen Z, Ding Q, Liu C, Wang J, Tian H, Li J, Zhang Z (2017) Atomic-scale mechanism of the θ’’→θ’ phase transformation in Al-Cu alloys. J Mater Sci Technol 33:1159–1164. https://doi.org/10.1016/j.jmst.2016.08.03110.1016/j.jmst.2016.08.031 ↗
48. Bourgeois L, Medhekar NV, Smith AE, Weyland M, Nie J, Dwyer C (2013) Efficient atomic-scale kinetics through a complex heterophase interface. Phys Rev Lett 111:046102. https://doi.org/10.1103/PhysRevLett.111.04610210.1103/PhysRevLett.111.046102 ↗
49. Jeenager VK, Pancholi V (2014) Influence of cell wall microstructure on the energy absorption capability of aluminium foams. Mater Des 56:454–459. https://doi.org/10.1016/j.matdes.2013.08.10910.1016/j.matdes.2013.08.109 ↗
50. Jun-Shan Z (2010) Chapter 5, creep of solid solution alloys. High temperature deformation and fracture of materials. Woodhead Publishing, Cambridge, pp 69–82
51. Andersen SJ, Marioara CD, Friis J, Wenner S, Holmestad R (2018) Precipitates in aluminium alloys. Adv Phys 3(1):1479984. https://doi.org/10.1080/23746149.2018.147998410.1080/23746149.2018.1479984 ↗
52. Wiengmoon A, Pearce JTH, Chairuangsri T, Isoda S, Saito H, Kurata H (2013) HRTEM and HAADF-STEM of precipitates at peak ageing of cast A319 aluminium alloy. Micron 45:32–36. https://doi.org/10.1016/j.micron.2012.10.00910.1016/j.micron.2012.10.009 ↗