Copyright©2006	The Japan Institute of Metals All rights reserved
Pubished by	The Japan Institute of Metals 1-14-32, Ichibancho, Aobaku, Sendai 980-8544, Japan
Publication date	February 28, 2006
Printed in Japan

Contents

APPLICATIONS AND INDUSTRIALIZATION

Automobile and aerospace

Improving Structural Crashworthiness Using Metallic Foams	............  1
G. Rausch, K. Stöbener
Space Applications for Highly Porous Materials	............  5
J. Baumeister, D. Labuhn, L. Pambaguian
Aluminium Foam Sandwich (AFS), Developments Driven by Customer Related Enhancements	............  9
H.-W. Seeliger
Production & Fabrication Technology Development of Aluminum Useful for Automobile Lightweighting	............  13
K. Ito, H. Kobayashi
Iron Based Cellular Structures—Status and Prospects	............  21
G. Stephani, O. Andersen, H. Göhler, C. Kostmann, K. Kümmel, P. Quadbeck, M. Reinfried, T. Studnitzky, U. Waag

Heat sink

Development of Lotus-Type Porous Copper Heat Sink	............  27
T. Ogushi, H. Chiba, H. Nakajima
Heat Transfer Capacity of Lotus-type Porous Copper Heat Sink	............  35
H. Chiba, T. Ogushi, H. Nakajima
Experimental Analysis of Multiphase Flow in Metallic Foam: Impact of Structure on Flow Properties	............  41
F. Topin, J.-P. Bonnet, L. Tadrist

Biomaterials

Biocompatibility of Lotus-type Porous Metals in Alveolar Bone	............  47
Y. Higuchi, Y. Ohashi, H. Nakajima
Effects of Extended Pore Direction and Stress Shielding on Biological Apatite Texture as Bone Quality after Insertion of Metallic Implants with and without Pores	............  51
T. Nakano, T. Kan, T. Ishimoto, Y. Ohashi, Y. Umakoshi, T. Hattori, Y. Higuchi, M. Tane, H. Nakajima
Porous Titanium Compacts as Biomaterials for Hard Tissue Replacement	............  55
Y. Sakamoto, K. Asaoka, M. Kon, T. Matsubara, K. Yoshida
Addition of Advanced Biocompatibility to a Porous Artificial Root	............  59
H. Nishikawa, T. Hayami, S. Hontsu, M. Kusunoki

Machine tools, burners and golf head

Machine Tools with Metal Foam	............  63
R. Neugebauer, T. Hipke
Application of Reticulated Metal Foam to Gas Fired Infrared Burners	............  69
E.J. Cookson, D.E. Floyd II
Manufacturing of Core of Golf Head by Applying Powder Metallurgy Route Method	............  73
K.Y. Liao, C.S. Kang, J.S. Shih

PHYSICS OF FOAMING

Metallic foams

Metal Foams: the Mystery of Stabilisation	............  75
J. Banhart
Processing Fundamentals of Fine Aluminum Foam Production from Liquid Metals	............  87
H. Nakae, K. Kadoi
Materials Issues in Foaming of Liquid Aluminium	............  95
A.A. Gokhale, S.N. Sahu, V.K.W.R. Kulkarni, B. Sudhakar, N.R. Rao
Effects of SiC Addition on Foaming Behavior and Mechanical Properties of AlSi7-TiH2 Powder Compacts	............  101
S. Esmaeelzadeh, A. Simchi, D. Lehmhus
Zirconium Hydride—a Possible Blowing Agent for Making Aluminum Alloy Foams	............  107
B. Matijasevic, O. Görke, H. Schubert, J. Banhart
Foaming Behavior of Precursors Made of Various Kinds of Al Alloy Powder	............  111
M. Ota, M. Kobashi, N. Kanetake
Foaming Characteristics of Al-Mg Alloy Foam	............  115
S.Y. Kim, K.H. Kang, Y.S. Um, B.Y. Hur
Rheology of the Al and Mg Alloys for Manufacturing Metal Foam	............  119
S.-H. Park, Y.-S. Um, S.-Y. Kim, B.-Y. Hur
Influence of Alloying Additions on Foaming Behaviour of Thixocast AlSi11 Precursor	............  123
J. Weise, O. Marchetto, M. Haesche, F. Garcia-Moreno, J. Banhart
The Role of the Gas Pressure on the Foaming of Metals Following the PM-route	............  129
F. Garcia-Moreno, N. Babcsan, J. Banhart
Optimising Process Strategies for Fraunhofer type Al-foams using Kinetic Analysis of Foaming Agent Variants	............  133
D. Lehmhus, M. Wichmann
The Effect of Compaction Method on the Expansion and Stability of Aluminium Foams	............  139
S. Asavavisithchai, A. Kennedy
An Introduction on Acquiring Kinetics Parameters of Titanium Hydride from Its TPD Spectrum	............  145
D.H. Yang, S.R. Yang, B.Y. Hur

Non-metallic foams

Foaming of Protein Stabilized Metal Powder Slurries	............  149
J. Babcsán-Kiss, A. Berthold, N. Babcsán, H. Schubert

PROCESSING TECHNOLOGIES FOR POROUS AND FOAMED METALS

Foaming of powder compacts

A New Generation of Materials and Their Production Methods	............  153
P. Schäffler
Advanced Pore Morphology (APM) Metal Foam—Process and Characteristics	............  157
K. Stöbener, J. Baumeister, G. Rausch
Three Dimensional Metallic Honeycomb Structure	............  161
M. Reinfried, U. Waag, G. Stephani, B. Kieback
Solid-state Foaming of Magnesium Alloys	............  165
C. Wen, M.R. Barnett, J. Vella, Y. Yamada
Foaming and Filling-in Behavior of Porous Aluminum in Hollow Components	............  169
M. Kobashi, R. Sato, N. Kanetake
Effect of Densification under Uni-Axial Compaction on Foaming Behavior of PM Precursors	............  173
L. Bonaccorsi, E. Proverbio
Effects of Processing Parameters on Pore Morphology of Combustion Synthesized Al-Ni Foams	............  177
N. Kanetake, M. Kobashi, R.-X. Wang
Modeling of Solid-State Foaming in Titanium	............  181
S.M. Openheimer, D.C. Dunand
Cell Structure Control of Porous Titanium Composite Synthesized by Combustion Reaction	............  185
M. Kobashi, K. Kuze, N. Kanetake
Processing Technology for High Porosity Closed Cell Metal Foam	............  191
T. Shimizu, K. Matsuzaki
Structure Development in Aluminum Foam Manufactured by Hot Rolling	............  195
S. Vatchiants, N. Manukyan

Foaming of melts

Replication (a.k.a. Space-holder) Processing of Highly Porous Materials	............  199
Y. Conde, J.-F. Despois, R. Goodall, A. Marmottant, L. Salvo, C.S. Marchi, A. Mortensen
Replicated Microcellular Aluminium with Spherical Pores	............  207
R. Goodall, A. Marmottant, J.-F. Despois, L. Salvo, A. Mortensen
Fabrication of Lotus-type Porous Metals by Continuous Zone Melting and Continuous Casting Techniques	............  211
S.-K. Hyun, J.-S. Park, M. Tane, H. Nakajima
Fabrication of Lotus-type Porous Carbon Steel by Unidirectional Solidification in Nitrogen Atmosphere	............  215
M. Kashihara, H. Yonetani, T. Kobi, S.-K. Hyun, H. Nakajima
Casting and Mechanical Properties of Lotus-type Porous Hastelloy X	............  219
K. Taguchi, M. Sato, A. Mizuta, Y. Matsuzaki, S.K. Hyun, H. Nakajima
Fabrication of Lotus-type Porous Silver by Unidirectional Solidification in Oxygen Atmosphere	............  223
T. Nakahata, S.-K. Hyun, H. Nakajima
Fabrication of Lotus-type Porous Ni3Al by Unidirectional Solidification	............  229
T. Ide, M. Tane, S.-K. Hyun, H. Nakajima
Fabrication of Lotus-type Porous NiTi Shape Memory Alloys	............  233
M. Sugiyama, S.K. Hyun, M. Tane, H. Nakajima
Effects of Processing Condition on Structure of Regular Porous Metals Fabricated by Directional Solidification	............  237
Y. Li, Y. Liu, H. Zhang, X. Wang
Some Theoretical Problems in Metal-Gas Eutectic Unidirectional Growth	............  241
Y. Liu, Y. Li, J. Wan, H. Zhang
Fabrication of Lotus-type Porous Silicon by Unidirectional Solidification in Mixture Gas of Hydrogen and Argon	............  247
T. Nakahata, S.-K. Hyun, H. Nakajima
Fabrication of Lotus-type Porous Alumina by Unidirectional Solidification	............  251
S. Ueno, L.M. Lin, S.K. Hyun, H. Nakajima
Current Activities and New Technologies of Aluminum Foam by Melt Route	............  255
T. Miyoshi, S. Nishi, S. Furuta, T. Hamada, K. Yoshikawa
Role of Oxidation during Blowing of Aluminium Foams by External Gas Injection	............  261
N. Babcsán, F. Garcia-Moreno, J. Banhart
Influence of Viscosity on Foamability of Aluminum Melts	............  267
K. Kadoi, M. Tayama, M. Yoshida, H. Nakae
Progress in Aluminium Foaming Technology: Application of Calcium Carbonate as Foaming Agent for Alporas and Powder Compact Techniques	............  273
A. Byakova, A. Sirko, K. Mykhalenkov, Y. Milman, S. Gnyloskurenko, T. Nakamura
Integral Foam Moulding of Light Metals	............  279
C. Körner, M. Hirschmann, H. Wiehler
A New Technique for Formation of Porous Metallic Materials by Using Metal Films	............  285
A. Watazu, T. Sonoda, K. Kato, T. Yamada, T. Asahina, N. Saito
Fabrication of Porous Media with a High Aspect Ratio by Solidification of Monotectic Alloys under a Magnetic Field	............  289
H. Yasuda, I. Ohnaka, B.K. Dhindaw, N. Takezawa, S. Fujimoto, T. Nagira, A. Tsuchiyama, T. Nakano, K. Uesugi
Fabrication of Open Cell Metal Foam Using Polymer Foam	............  293
S. Hongmin, B.-K. Park, B.-Y. Hur

Sintering and other methods

Adjusting the Pore Structure of Open Porous Metallic Foams Produced by the Slip Reaction Foam Sintering (SRFS)—Process	............  295
S. Angel, W. Bleck, P.-F. Scholz
Porous Metals Using Polyurethane Foam Template	............  301
K. Harada, A. Yamakawa
Density-Graded Aluminum Foams	............  305
A.H. Brothers, D.C. Dunand
Production of Micro Porous Metal Components by Metal Injection Molding Based Powder Space Holder Method	............  311
K. Nishiyabu, S. Matsuzaki, S. Tanaka
Superior Nickel Foam Production: Starting from Raw Materials Quality Control	............  317
V. Paserin, J. Shu, S. Marcuson
Preparation of Metallic Porous Materials by Oxidation-Reduction Liquid Sintering of Fe-SnO2 Mixture	............  321
T. Takahashi
Effectiveness of Micro Porous Metal Components with Functionally Graded Structures	............  325
K. Nishiyabu, S. Matsuzaki, S. Tanaka
Advanced Metal Powder Injection Molding for Multilayered Micro Porous Titanium Components	............  329
K. Nishiyabu, S. Matsuzaki, S. Tanaka
Cell Structure Control of Porous Material Made of Steel Fiber by Imposition of a Static Magnetic Field	............  333
Y. Chino, K. Sassa, Y. Yamada, M. Hakamada, M. Mabuchi, S. Asai
Technology of Producing Aluminum Foam from Machined Chips	............  337
S. Tsuda, M. Kobashi, N. Kanetake
The Spark Plasma Sintering Method using Laminated Titanium Powder Sheet for Fabricating Porous Biocompatible Implants	............  341
K. Maekawa, T. Hayashi, K. Hanyu, K. Umeda, T. Murakami
Fabrication Method for Metallic Closed Cellular Materials	............  345
S. Kishimoto, N. Shinya
Superplastic Forming and Foaming Process of Aluminum Alloy Foams	............  349
K. Kitazono, S. Kamimura, E. Sato, K. Kuribayashi
Cell Morphology of Closed-Cell Magnesium Foam Manufactured by Bulk Foaming Process	............  355
Y. Kikuchi, K. Kitazono, E. Sato, K. Kuribayashi
Powder-Metallurgical Process for Fabricating Metallic Microchannel Devices	............  359
T. Ohmi, M. Takatoo, M. Iguchi, K. Matsuura, M. Kudoh
Unusual Wetting of Liquid Metals in Porous Thin Layer Formed on Iron Substrate	............  365
N. Takahira, T. Tanaka
Processing and Characterization of a New Composite Metal Foam	............  369
A. Rabiei, L. Vendra, N. Reese, N. Young, B. Neville
Pressure Sintering of Metallic Hollow Sphere Compacts: Experiment and Simulation	............  375
K. Shinagawa, H. Yoshimura, Y. Mihara, Y. Sukegawa, K. Murakami
Metallic Hollow Sphere Structure Bonded by Adhesion	............  381
H. Yoshimura, K. Shinagawa, Y. Mihara, Y. Sukegawa, K. Murakami
New Methods for Fabricating Truss Periodic Cellular Metals Using Wires	............  387
J.-H. Lim, J.-G. Jung, J.-D. Lim, K.-J. Kang
Processing of Porous Aluminum by the Spacer Method	............  393
M. Hakamada, T. Nomura, T. Kuromura, Y. Yamada, M. Mabuchi

CHARACTERIZATION AND PROPERTIES

Characterization of structures by tomography and image analysis

The Structure of Random Foam	............  397
A.M. Kraynik
Structural Properties Measurement: A Morphological Analysis Tool for Transport Properties Determination	............  403
J. Vicente, F. Topin, L. Tadrist
Image-Based Mechanical Analysis of Dynamic Deformation and Damage Behaviors in an Aluminium Foam Using Synchrotron X-Ray Microtomography	............  409
H. Toda, N. Kuroda, T. Ohgaki, M. Kobayashi, T. Akahori, M. Niinomi, T. Kobayashi, K. Uesugi, K. Makii, Y. Aruga
In-situ X-ray Tomography Investigation of Replicated Aluminium Foams: Quantitative Analysis of Localisation Using 3D Strain Mapping	............  415
A. Marmottant, J.-F. Despois, L. Salvo, E. Maire, M. Bornert, A. Mortensen
Characterisation of Aluminium Foams Using X-Ray Computed Tomography	............  419
Y. Yamada, T. Banno, Z. Xie, C. Wen
Measurement of Pore Length of Lotus-type Porous Nickel	............  423
H. Onishi, S.-K. Hyun, H. Nakajima

Elastic properties

Elastic Response of Titanium Foams During Compression Tests and Under Laser-Ultrasonic Probing	............  427
L.-P. Lefebvre, A. Blouin, S.-M. Rochon, M.N. Bureau
Calculation Methods on Young's Modulus of Closed-cell Foams	............  433
Y.S. Um, B.Y. Hur, H. Arai
In Situ-Formed Porous Titanium Alloys	............  437
G. He, M. Hagiwara

Deformation and energy absorption

Space-filling Polyhedra as Mechanical Models for Solidified Dry Foams	............  441
T. Daxner, R.D. Bitsche, H.J. Böhm
A New Material Model for Cellular Aluminium	............  447
M. Wicklein, K. Thoma
The Yield Function for Porous Materials with Cubic Symmetry	............  453
A.H. Wilkins, A.P. Roberts, D.L.S. McElwain
Experimental Techniques for Investigation of the Elasto-Plastic Transition Zone of Porous Materials	............  457
A. Öchsner, T. Fiedler, J. Grácio, G. Kuhn
Yield Strength of Lotus-type Porous Iron Fabricated under Hydrogen or Nitrogen Atmosphere	............  463
M. Tane, T. Ichitsubo, S.-K. Hyun, H. Nakajima
Compressive Behavior of Cubic Spherical FE Model with Different Wall Thickness Ratio for Al-Alloy Foams	............  467
K. Tunvir, A. Kim, S.-S. Cheon
Design of Energy Absorbing Device Based on Shape Memory Alloys	............  473
Y. Zhao, M. Taya
Experimental Characterisation of the Deformation in Hollow Sphere Structures	............  479
O. Friedl, C. Motz, J. Färber, M. Stoiber, R. Pippan
A Study on the Mechanism of Strength Enhancement under Impact Loading of Cellular Materials	............  483
H. Zhao, S. Abdennadher, I. Elnasri
Material Models for Deformation and Fracture Behaviour of Aluminium Foams	............  489
D.-Z. Sun, F. Andrieux
Structure of Aluminium Foams and Relation to Mechanical Properties	............  495
U. Martin, U. Mosler, D. Lehmhus, A. Müller, G. Heinzel
Fabrication and Mechanical Properties of Open-cell Al-Si Foam	............  499
B.-K. Park, S.-Y. Kim, Y.-S. Um, B.-Y. Hur
Effect of Processing Route on Energy Management of Foamed Al Alloys	............  503
Y. Milman, A. Byakova, Y. Podrezov, D. Verbilo, T. Nakamura, S. Gnyloskurenko
Improving the Mechanical Response of Aluminium Foams in Compression by Using Internal Reinforcements	............  509
E. Solórzano, M.A. Rodríguez-Pérez, J.A. Reglero, J.A. de Saja
Structural and Dynamical Evaluation of Highly Porous Aluminum Material Prepared by Space-Holder Method	............  513
T. Asahina, I. Jeon, K. Kato, T. Sonoda, Y. Yamada
Effect of the Matrix Strength on the Energy Absorption in Aluminum Foam	............  517
Y. Aruga, K. Makii, T. Miyoshi, S. Nishi
Aluminium Foams as a Filler for Leading Edges: Bird Strike Damage Tests	............  521
M.A. Rodríguez-Pérez, E. Solórzano, J.A. de Saja, J.A. Reglero, E. Porras, A. Fernández
Mechanical Properties of Lotus-type Porous Carbon Steel by Continuous Zone Melting Method	............  525
T. Kujime, S.-K. Hyun, H. Nakajima
Tensile Properties of Lotus-type Porous Copper: Effect of Specimen Dimensions	............  529
H. Sueno, M. Tane, J.-S. Park, S.-K. Hyun, H. Nakajima
Dynamic Strength in Uniaxial Compression of Closed Cell Aluminum Foam	............  533
T. Hamada, H. Kanahashi
Energy Absorption of Cellular Aluminum Alloys at High Strain Rates	............  539
T. Mukai
Crushing Behaviour and Mechanical Properties of Foam-Filled Circular Aluminium Tubes	............  543
T. Banno, Z. Xie, Y. Yamada, C. Wen
The Effects of Inhomogeneity on the Buckling Behavior of Metal Foams	............  547
F. Adziman, T. Dirgantara, H. Inoue, K. Kishimoto, T. Hashimura
Effect of Applied-Stress Direction on Compressive Properties of Lotus-type Porous Stainless Steel	............  551
T. Ide, M. Tane, T. Ikeda, S.-K. Hyun, H. Nakajima
Relationship between Specimen Size and Compressive Yield Strength of Lotus-type Porous Copper	............  555
J.-S. Park, H. Sueno, S.-K. Hyun, M. Tane, H. Nakajima, Y.-S. Um, B.-Y. Hur, F. Ono

Fracture and fatigue

Isothermal and Thermomechanical Fatigue Behavior of Open-Cell Metal Sponges	............  559
U. Krupp, A. Ohrndorf, T. Guillén, H.-J. Christ, S. Demiray, W. Becker, J. Hohe
Assessment of Fatigue Behaviour of Aluminium Foams by Synchrotron X-ray Microtomography	............  565
T. Ohgaki, H. Toda, M. Kobayashi, K. Uesugi, T. Kobayashi, M. Niinomi, T. Akahori, K. Makii, Y. Aruga
Compression Characteristics of Metallic Hollow Spheres with Pipe Overcoat	............  571
Y. Sukegawa, U. Waag, K. Murakami, H. Yoshimura, K. Shinagawa, Y. Mihara
Mechanical Properties of Porous Aluminum Fabricated by the Spacer Method	............  577
M. Hakamada, Y. Yamada, T. Nomura, T. Kuromura, M. Mabuchi
Fatigue of Porous Aluminum Fabricated by the Spacer Method	............  581
M. Hakamada, Y. Yamada, T. Kuromura, M. Mabuchi
Fatigue Behavior of Lotus-type Porous Copper	............  585
S. Sasaki, H. Seki, S. Yamazaki, T. Yasuno, M. Otsuka, M. Murakami, S.K. Hyun, M. Tane, H. Nakajima
Fracture Behavior of Metal Foam Made of Recycled MMC by the Melt Route	............  589
E. Amsterdam, N. Babcsán, J.T.M. De Hosson, P.R. Onck, J. Banhart
Mechanical Properties for Porous Al2O3/Al Composite Fabricated by an Al(OH)3/Al mixture	............  593
Y. Tanaka, Z.-Y. Deng, Y. Kagawa

Sound absorption, thermal conductivity and others

Electrical Conductivity of Lotus-type Porous Nickel: Measurements and Effective-Mean-Field Theory	............  597
M. Tane, S.-K. Hyun, H. Nakajima
Steady-State Thermal Characteristics of Transpiration Cooling System Using Open-Cellular Porous Materials in a Radiative Environment	............  601
K. Kamiuto, K. Unoki, J. Andou
Sound Absorption of Lotus-type Porous Magnesium	............  607
Z.-K. Xie, Y. Yamada, T. Banno, S.-K. Hyun, M. Tane, Y. Okuda, H. Nakajima
Vibration-Damping of Lotus-type Porous Magnesium	............  611
Z.-K. Xie, Y. Yamada, T. Banno, M. Tane, S.-K. Hyun, H. Nakajima
Tribological Behaviour of Lotus-type Porous Metal	............  615
T. Kato, T. Nakahata, H. Nakajima
Development of Sub-micron Structure Porous Metals by Nanoscale Powder Space Holder Method	............  619
K. Nishiyabu, S. Matsuzaki, S. Tanaka
Effect of Dissolved Hydrogen on Corrosion Behavior of Lotus-type Porous Stainless Steel	............  623
M. Fuseya, T. Nakahata, S.-K. Hyun, S. Fujimoto, H. Nakajima
Mechanical and Sound Absorption Properties of Mineral Wool and Al Foam Sandwich Board	............  627
K.-H. Kang, S.-J. Park, Y.-S. Um, B.-Y. Hur

SECONDARY OPERATIONS

Joining

Ultrasonically Welded Aluminium Foams/Sheet Metal—Joints	............  631
C. Born, G. Wagner, D. Eifler
Techniques for Melt Support during Laser Welding of Aluminum Foam	............  635
H. Haferkamp, D. Herzog, A. Ostendorf, J. Bunte, O. Meier
On the Joining of Aluminum Foams and Aluminum Foam Sandwiches	............  639
L. Filice, L. Fratini, D. Umbrello
Joining Aluminium Foams by Using Adhesives	............  643
M.A. Rodríguez-Pérez, J.A. Reglero, E. Soló:rzano, E. Porras, A. Fernandez, J.A. de Saja
Numerical Simulation of Laser Fusion Zone Profile of Lotus-type Porous Metals	............  647
T. Tsumura, T. Murakami, H. Nakajima, K. Nakata
Laser Welding of Lotus-type Porous Iron	............  651
H. Yanagino, T. Tsumura, H. Nakajima, K. Nakata

Coating

Formation of Ceramic Coatings on Porous Metals by Electrophoretic Sol-Gel Deposition	............  655
M. Inoue, S.-K. Hyun, K. Suganuma, H. Nakajima

Surface modification

A Novel Surface Modification Process for Porous Metals using Friction Phenomena	............  659
Y.-J. Kwon, I. Shigematsu, N. Saito

NANOPOROUS METALS

An Overview on Characterization and Mechanical Behavior of Nanoporous Gold	............  663
A.M. Hodge, J.R. Hayes, J.A. Caro, J. Biener, A.V. Hamza
Preparation of Nanoporous Gold Film as a Nanofilter	............  667
H. Tanimoto, Y. Ishibashi, H. Mizubayashi