Integral Foam Molding of Light Metals

Integral Foam Molding of Light Metals
Technology, Foam Physics and Foam Simulation
With 143 Figures and 8 Tables
Carolin Koerner
Contents
Preface Vii
I Technology 1
1 Introduction 5
1.1 Integral Foam . 5
1.2 Polymer Integral Foam Molding . 13
2 Integral Foam Molding of Metals 19
2.1 Basic Considerations . 20
2.2 Admixing of the Blowing Agent . 24
2.3 Low Pressure Integral Foam Molding 27
2.4 High Pressure Integral Foam Molding 32
2.5 Base Materials 35
2.6 Synopsis 41
3 Structure and Properties 45
3.1 Density Profiles 45
3.2 Foam Structure Evolution 55
3.3 Mechanical Properties 64
3.4 Synopsis 71
Ii Physics 73
4 Physics of Foaming 77
4.1 Governing Equations . 78
4.2 Bubble Dynamics . 83
4.3 Stabilization Mechanisms . 89
5 Evolution Laws 103
5.1 Fundamentals . 104
5.2 Non-stabilized Evolution . 106
Xicontents
5.3 Stabilized Evolution . 114
5.4 Synopsis 121
6 Endogenous Stabilization 123
6.1 Disjoining Pressure 124
6.2 Stratification . 130
6.3 Foam Evolution 131
6.4 Synopsis 136
Iii Numerical Simulation 139
7 Theoretical Approach 143
7.1 State-of-the-art 144
7.2 Physical Model 148
7.3 Lattice Boltzmann Approach . 152
8 Lbm for Free Surface Flow 163
8.1 Free Surface and Fluid Advection 164
8.2 Interface Boundary Conditions 167
9 Lbm for Foam Evolution 171
9.1 Gas Bubbles and Gas Transport . 171
9.2 Interfacial Forces . 175
9.3 Foam Formation Phenomena . 177
A Gas Supply and Gas Diffusion 185
A.1 Generalized Johnson-mehl-avrami Approach 185
A.2 Gas Diffusion . 187
B Miscellany 189
B.1 Foaming Pressure . 189
B.2 Mean Cell Diameter . 191
B.3 Curvature Calculation 193
C Material Parameters 195
Symbols 199
Bibliography 203
Index
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