Fabrication of various types of ADC12 aluminum alloy die castings containing different amount of gases and porous aluminum fabricated by friction stir processing

Various types of ADC12 aluminum alloy die casting plates containing different amounts and types of gases were fabricated by varying the die casting conditions. Porous aluminum without the use of a blowing agent was fabricated by friction stir processing using the gases contained in the fabricated ADC12 aluminum alloy die casting plates. The effect of the amount of gases contained in the die castings on the foaming efficiency and the pore structures of obtained porous aluminum observed by X-ray CT inspection were investigated. It was shown that, although the expansion efficiency of each type of gas was not clear, the total amount of gases and porosity of obtained porous aluminum has good correlation. A porosity of approximately 60% was obtained with small area of pores and highly spherical.