Improvement of the foaming process for 4045 and 6061 aluminium foams by using the Taguchi methodology

Taguchi methodology has been applied to the production process of aluminium foams to investigate the variability detected in several properties (including bulk density, outward appearance and density homogeneity along foaming direction), for foaming tests carried out under identical conditions. The analysis of the process has been performed separately for two different alloys, the 4045 and 6061. The results have allowed finding the main factors that influence those properties. In addition, it has been possible to establish those foaming conditions able to minimize the variability in density, to improve the outward appearance and to obtain a higher homogeneity in density, all at the same time. Different final factors have been found for the two alloys; such differences have been explained in terms of the different viscosity of the aluminium melts as well as the different content of foaming agent.