Abstract
Aluminum foam is expected to be a leading candidate for lightweight parts due to its light weight and excellent shock-absorption and sound-absorption properties. In order to use it as a part, it is essential to form it into the desired shape. However, the cell walls that form the pores are composed of thin aluminum. When aluminum foam is formed, the cell walls easily fracture and the pores collapse. This results in the loss of the properties of the aluminum foam. Past studies have shown that press forming aluminum foam immediately after foaming, while it is still in the softened state, prevents cell wall failure and pore deformation. In this study, we attempted to perform a continuous process from the foaming of the precursor to the press forming of aluminum foam for three precursors, for the purpose of the continuous production of aluminum foam with desired shapes. It was shown that it is possible to continuously and sequentially foam the precursors by heating and press forming the foamed samples. In addition, aluminum foam with a similar shape, porosity, and pore structure can be fabricated using the continuous process. Also, it was shown that aluminum foam with complex shapes can also be continuously fabricated by using a complex-shaped die. Furthermore, it was indicated that the use of a die in press forming can shorten the cooling time and reduce the production time.