Aluminium Foams Fabricated by the PM Route using Nickel-coated Titanium Hydride Powders of Controlled Particle Size

To establish the effect of reducing the temperature mismatch between the TiH2 decomposition temperature and the aluminium melting point on the foams morphological features and their mechanical compression behavior, a nickel coating on TiH2 powders was used as a hydrogen diffusion barrier and the size of TiH2 powders was controlled to modify the hydrogen evolution temperature.;Coating produced a continuous and homogeneous deposit of 96.5 wt.% nickel and reduced the initial temperature mismatch by approximately 70°C. Additionally, the coating adhesion proved to be good enough to withstand the mixing and compaction processes. Nickel-coated TiH2 powders generated foams with a more homogeneous and reproducible pore structure than foams produced with powders in the as-received and passivated condition. On the other hand, the hydrogen evolution onset of TiH2 shifted towards higher temperatures as the particle size increased. The particle size influenced the foam expansion and the porosity features. Powders of larger particle size produced foams with a more uniform pore distribution and size. Finally, compression tests on skinless foams containing nickel displayed quasi-horizontal energy regimes with longer stroke lengths than the rest, however the final energy absorption efficiencies (above 7.2 kJ·kg-1) were not remarkably increased.;The nickel diffusion barrier was produced by an electroless deposition technique and the hydrogen evolution behavior of coated powders was investigated by thermogravimetrical analysis. The effect of particle size was determined with powders of five particle size fractions along with powders of different particle size obtained from a supplier. Foamable precursors were obtained by hot pressing a mix of aluminium powders with 1 wt.% of TiH2 powders and foams were fabricated at 750 and 800 °C. The foams mechanical strength was investigated by uni-axial compression on foam cylinders with and without outer skin.