Fabrication optimization of Al 7075/expanded glass syntactic foam by cold chamber die casting

C. Bolat*, A. Goksenli

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

7 Citations (Scopus)


Recently, aluminum matrix syntactic foams (AMSFs) have become notably attractive for many different industrial areas like automotive, aerospace, construction and defense. Owing to their low density, good compression response and perfect energy absorption capacity, these advanced composite materials are also considered as strong alternatives to traditional particle reinforced composites and metal foams. This paper presents a promising probability of AMSF fabrication by means of industrial cold chamber die casting method. In this investigation, contrary to other literature studies restricted in laboratory scale, fully equipped custom-build cold chamber die casting machine was used first time and all fabrication steps were designed just as carried out in the real industrial high pressure casting applications. Main casting parameters (casting temperature, injection pressure, piston speed, filler pre-temperature and piston waiting time) were optimized in order to obtain flawless AMSF samples. The density alterations of the syntactic foams were analyzed depending upon increasing process values of injection pressure, piston speed and piston waiting time. In addition, macroscopic and microscopic investigations were performed to comprehend physical properties of fabricated foams. All these efforts showed almost perfect infiltration between filler particles at the optimized injection parameters.

Original languageEnglish
Pages (from-to)112-118
Number of pages7
JournalArchives of Foundry Engineering
Issue number3
Publication statusPublished - 2020

Bibliographical note

Publisher Copyright:
© 2020 Polish Academy of Sciences. All rights reserved.


This article was supported by The Scientific and Technological Research Council of Turkey (TÜBİTAK) with the project ID of 116M533. We also would like to thank to Omnis Composite Limited Company for rapid supplying of high quality EG spheres.

FundersFunder number
Türkiye Bilimsel ve Teknolojik Araştirma Kurumu


    • Aluminium alloys
    • Cold chamber die casting
    • Expanded glass
    • Process optimization
    • Syntactic foams


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