3-Dimensional Shaped Aluminium Foam Sandwiches

  1. Dr. P. J. Winkler
  1. J. Baumeister1,
  2. F. Baumgärtner2,
  3. P. J. Gers3 and
  4. W. Seeliger4

Published Online: 23 DEC 2005

DOI: 10.1002/3527606025.ch8

Materials for Transportation Technology, Volume 1

Materials for Transportation Technology, Volume 1

How to Cite

Baumeister, J., Baumgärtner, F., Gers, P. J. and Seeliger, W. (2000) 3-Dimensional Shaped Aluminium Foam Sandwiches, in Materials for Transportation Technology, Volume 1 (ed P. J. Winkler), Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim, FRG. doi: 10.1002/3527606025.ch8

Editor Information

  1. DaimlerChrysler AG, Forschung und Technologie, Postfach 800 465, 81663 München, Germany; Tel.: 089–607 22393; Fax: 089–607 28627

Author Information

  1. 1

    Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung, Bremen, Germany

  2. 2

    Schunk Sintermetalltechnik, Gießen, Germany

  3. 3

    Honsel AG, Meschede, Germany

  4. 4

    Wilhelm Karmann GmbH, Osnabrück, Germany

Publication History

  1. Published Online: 23 DEC 2005
  2. Published Print: 20 APR 2000

Book Series:

  1. EUROMAT 99

ISBN Information

Print ISBN: 9783527301249

Online ISBN: 9783527606023



  • transportation technology;
  • materials;
  • automotive;
  • 3-dimensional shaped aluminium foam sandwiches


3-dimensional shaped sandwich panels with a very high stiffness can be produced in an elegant way by combining aluminium face sheets with an aluminium foam core

For this, a mixture of aluminium powder and a foaming agent is compressed to a semi-finished product of nearly vanishing porosity by extrusion, powder rolling or hot isostatic pressing. The resulting foamable semi-finished aluminium material is roll clad with sheets of conventional steel or aluminium. As a result a precursor material is obtained consisting of two face sheets which are metallurgically bonded to the foamable core layer. This sandwich precursor material can be shaped into a 3-dimensional part by conventional techniques, e.g. by stamping or deep drawing. In a final step the foamable precursor material is heated up to the melting point of the core layer thus initiating its expansion into the desired 3-dimensional shaped sandwich structure. The porosity of the foamed core layer is in the range from 80–90 % so that the integral density of the sandwich structure can be as low as 0,7 g/cm3.

The sandwich materials combine the low weight and high bending stiffness with the advantages of the face sheets, i.e. the high strength and weldability. The manufacturing process will be described in detail and the material properties will be shown. Current and future possible applications will be outlined as well as concrete parts produced up to date.