Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Fundamental Investigations for Manufacturing of Lightweight Sandwich Components with Aluminium Foam Core

Datum: 26.09.2005



  • Prof. Dr.-Ing. Dr.-Ing. E.h. mult. Dr.h.c. M. Geiger
  • Prof. Dr.-Ing. R.F. Singer

In the automotive industry substantial measures were taken in recent years in terms of lightweight construction. Besides increasing requirements relating to weight reduction to minimise fuel consumption and emission output drivers of this efforts are the also the rising demands of customers for higher comfort and improved passenger safety and the herewith contrariwise growing vehicle weight according to necessary integration of additional components. andwich components are characterised by high stiffness and at the same time low weight of the part. Furthermore aluminium foams due to their material properties show an excellent potential to be used as the core structures in such composites. However the forming properties of aluminium foams are very poor. Main goal of this work is to solve the existing deficit of cognition relating to forming of aluminium foam and to develop an adapted process and tool layout. Further intention is to make available knowledge about suitable joining techniques that enable manufacturing of sandwich components made of aluminium foam and sheet metal materials. To achieve these objectives within this work the material behaviour and the forming properties of aluminium foam at elevated temperatures are investigated. To qualify appropriate methods for manufacturing sandwich parts different joining techniques are characterised and evaluated regarding to their applicability.