Casting Process for the Production of Foamed Magnesium Structural Parts

  1. B. Jouffrey
  1. H. Haferkamp1,
  2. D. Bormann1,
  3. M. Niemeyer1 and
  4. Fr.W. Bach2

Published Online: 9 MAY 2006

DOI: 10.1002/3527606165.ch7

Microstructural Investigation and Analysis, Volume 4

Microstructural Investigation and Analysis, Volume 4

How to Cite

Haferkamp, H., Bormann, D., Niemeyer, M. and Bach, Fr.W. (2000) Casting Process for the Production of Foamed Magnesium Structural Parts, in Microstructural Investigation and Analysis, Volume 4 (ed B. Jouffrey), Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim, FRG. doi: 10.1002/3527606165.ch7

Author Information

  1. 1

    Institut für Werkstoffkunde, Universität Hannover, Germany

  2. 2

    Lehrstuhl für Werkstofftechnologie, Universität Dortmund, Germany

Publication History

  1. Published Online: 9 MAY 2006
  2. Published Print: 20 APR 2000

Book Series:

  1. EUROMAT 99

ISBN Information

Print ISBN: 9783527301218

Online ISBN: 9783527606160



  • microstructural investigation;
  • metallic foams;
  • foamed magnesium structural parts;
  • production;
  • casting process


Porous and cellular metallic materials gain renewed attention as structural materials, particularly because of their very good relation between stiffness-to-weight. Different methods to produce metallic foams are known. Either the metallic foam is produced in an expenditural process sequence or only simply shaped parts may be produced in continuous processes. The long process sequence causes high costs so that metallic foam structural parts are used for special applications only. Lower costs of metallic foam structures could lead to the break-through in extensive applications. A casting process for the production of foamed magnesium is presented on the one hand to lower the costs for the production and on the other hand for a further weight reduction. By the use of magnesium with a density of l.74 g/cm3 a weight reduction of about 30 % compared with an aluminum foam with the same structure can be attained.

The magnesium alloy is molten up in an autoclave under argon atmosphere. To prevent contamination with foreign atoms one way of foaming magnesium is to use argon as foaming gas. Argon is supplied to the melt stream and homogenized in a static mixer. The two-phase current leaving the static mixer is a liquid magnesium foam that can be influenced by the volume flow of the magnesium and the gas. Controlled cooling within the mold increases the viscosity of the matrix material magnesium so that the foam is stabilized. This process has a very short process sequence because the foaming gas is supplied additionally to the casting process.

The result are near-net-shape semi finished products.