Cell size prediction of a closed aluminum foam

In order to predict foam size of a closed cell aluminum foam produced by air-foaming aluminum melt, three-dimensional static and dynamic simulations of bubble formation process were conducted in a polyvinyl alcohol solution with varied viscosities. The variables affecting flow nature and bubbling characteristics of compressed air injected into the solution were all investigated, and numerical models were developed for the prediction of bubble size in both static and dynamic foaming conditions. By modification of the dynamic model, a numerical equation was established, accounting for all the geometric, physical and hydromechanical factors of processing the aluminum foam. Moreover, the resulting numerical model predicting foam size of the closed cell aluminum foam was verified and modified by comparison to the results from practical foaming process under different production conditions. The finalized model of foam size prediction has strong correlation with the experimental data.