New foam stabilizing additive for aluminium

Liquid metals are mostly made foamable by Ca additions followed by a thickening period. There is a need for an additive that can be easily admixed to an aluminium alloy melt and makes this melt foamable. We have selected aluminium-based grain refiner composites to test their foamability. TiB 2, TiC or TiAl3 particles were produced in the melt by flux-assisted melting using fluoride salts. The particle size was kept below 1 μm for TiB2 and TiC and around 10 μm for TiAl3. The composites were heated to above their melting point (700°C) and were then foamed by either the addition of TiH2 or by injecting gases into the melt directly. Foams were successfully produced using TiB2 and TiC particles, while TiAl3 did not lead to any foam. Foam stability increased from TiB2 to TiC. Ex-situ characterisation of the foams by SEM showed that the particles segregate to the surfaces of the cell walls and lead to almost dense coverages there. Even after dilution of the initial composite a significant amount of foam can be still produced, indicating that these composites are suitable foam stabilizing additive for aluminium alloys and that foams based on small volume fractions of non-metallic additives can be produced.