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<p>Composite materials made from aluminum foam are increasingly utilized in aerospace and automotive industries due to their low density, high energy absorption capacity, and resistance to corrosion. Additive manufacturing processes offer several advantages over conventional manufacturing techniques, including the capability to fabricate significantly more geometrically complex components without the need for costly tooling. Direct Energy Deposition processes, such as DED-Arc/Wire Arc Additive Manufacturing (WAAM) facilitate the additive production of near-net-shape components at high build rates. This paper proposes a novel, cost effective and easy to implement additive manufacturing approach for highly porous aluminum using standard filler wires and equipment as well as H<sub>2</sub>-infused shielding gas.</p>

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Additive manufacturing of aluminum foams via H2-infused shielding gas: technological potential and process evaluation

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年5月7日

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  • Marcel Köhler,
  • Hannes Blaschke,
  • Sven Jüttner

摘要

Composite materials made from aluminum foam are increasingly utilized in aerospace and automotive industries due to their low density, high energy absorption capacity, and resistance to corrosion. Additive manufacturing processes offer several advantages over conventional manufacturing techniques, including the capability to fabricate significantly more geometrically complex components without the need for costly tooling. Direct Energy Deposition processes, such as DED-Arc/Wire Arc Additive Manufacturing (WAAM) facilitate the additive production of near-net-shape components at high build rates. This paper proposes a novel, cost effective and easy to implement additive manufacturing approach for highly porous aluminum using standard filler wires and equipment as well as H2-infused shielding gas.