Strong lightweight Innovative lightweight constructions of aluminium foam. Sandwiches Panels Foam filled profiles 3D shaped elements

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1 Strong lightweight Innovative lightweight constructions of aluminium foam Sandwiches Panels Foam filled profiles 3D shaped elements

2 Table of Contents Company Aluminium foam Product advantages Series production Product solutions Industrial solutions Values & properties Consultation & planning

3 Series producer for aluminium foam systems With our Havel Lite series, Havel metal foam has specialised in the development and production of aluminium foam and aluminium foam sandwiches a highly innovative lightweight material. Processing technologies bending, welding, milling, drilling, mechanical processing We have worked together with the Fraunhofer Institute for Machine Tools and Forming Technology to develop unique production technology that uses this modern material on an industrial scale. Innovative lightweight construction solutions can be realised for various sectors using the versatile Havel Lite range m²/a Production capacity Technical equipment Infrared ovens, electrically heated continuous furnaces, CNC milling systems 5 COMPANY UNIQUE THROUGHOUT THE WORLD S E R I E S P R O D U CT I O N FOR FOUR ALUMINIUM FOAM TECHNOLOGIES Unique The only manufacturer in the world who produces four different aluminium foam technologies in series production. Services FEM calculations Series production Versatile Competent Innovative Research & development Product solutions Further processing New, cost-effective industrial solutions that revolutionise lightweight construction. Unique production technology for joined metallic materials and components. Independent R & D department for new projects.

4 Aluminium foam An innovative material with unique properties Nature is once again the model for the development of a progressive material. The idea of metallic light construction is based on foam. More precisely, aluminium foam is produced from aluminium and this is used, which in itself is a light metal, to obtain an even lighter material through gas cavities. The practical value of lightness is clear. But how do lightness and stability fit together? They do. Efficiency, functionality and aesthetics are playing an ever-important role in product design and in many industrial sectors. And also in an environmental-political regard, rethinking material selection is increasingly in demand. Cavities filled with foam as well as a composition of metal plates and aluminium foam - in the form of a sandwich - offer a forward-looking alternative to fibre composites, pure aluminium, steel and other materials. 7 Application example of a sandwich as a floor plate ALUMINIUM FOAM Can be welded Rigid Metallic bond mm cover sheets Aluminium foam core Cover sheets with various alloys and coats (e.g. paint, marble, wood, wallpaper) Example application: Foamed steel profile

5 Strong lightweight Aluminium foam is lighter than water and still a stable, metallic material. It is an important material for lightweight constructions in industries and areas where there are high, but cost-effective requirements for the material and at the same time the energy factor should be optimised, for example, through a reduction in weight. Cellular structures found throughout nature serve as an example. The cellular structure has closed pores, composed of stochastically distributed cavities. They are therefore not similar to a beehive structure, but rather are irregular like corals or bones. These material are very light, yet possess remarkable stiffness and stability properties, which can also be achieved with aluminium foam and result in advantages in different industrial sectors. Bend test Comparison of steel with steelaluminium foam sandwich (SAS) SAS: signifi cantly less bending for the same weight (273 g) Steel, Bending 10 mm Steel-aluminium foam sandwich (SAS), Bending 0.3 mm High bending stiffness with low weight Comparison of steel sheet with a sandwich for the same weight Steel sheet x x 3 mm 3 Steel-aluminium foam sandwich x x 12 mm 3 (1 mm steel plate) 9 ALUMINIUM FOAM Assumption Same weight Weight 100 % 100 % Bending stiffness 100 % % A comparison of the deformation of a steel sheet and a sandwich with the same mass (approximately 4 kilograms) and same dimensions showed a maximum deflection of 7.2 mm with the steel sheet and only 0.3 mm with the sandwich.

6 Advantages of aluminium foam our 2+1 advantages Low weight and high mechanical durability require innovative lightweight construction solutions. Combined with at least one of the other unique advantages of aluminium foam, completely new and cost-efficient solutions are possible for the industry. Lightweight + High mechanical durability Energy absorption/good crash behaviour Excellent vibration damping Noise-absorbing Non-flammable (HL3 standard in accordance with EN 45545) + At least one product advantage of aluminium foam Can be welded Good electromagnetic shielding Further mechanical processing is easy to carry out (drilling, sawing, milling, welding) Foam-filling possible for inserts, threads, bolts (SAS) 100% recyclable Can be repaired Very good at conducting heat 11 PRODUCT ADVANTAGES SAS production technology: directly foamed bolts and nuts = New and cost-efficient solutions for lightweight construction made of aluminium foam The sandwich construction with aluminium foam also offers practical solutions for sectors requiring mobility and flexibility. Through the high bending strength and therefore higher mechanical stability than massive sheets, it is possible to build self-supporting structures with an optimal usage of space and simultaneously low total weight, for flexible parts like ramps, attachments, lifting platforms and lifts as well as temporary constructions like mobile parking lots, trade fair booths or bridges.

7 Series production Produce aluminium foam technologies in series? With ease! Havel metal foam is the first and only manufacturer to produce four different aluminium foam technologies in series production even large quantities with reproducible product qualities. 13 SERIES PRODUCTION UNIQUE THROUGHOUT THE WORLD S E R I E S P R O D U CT I O N FOR FOUR ALUMINIUM FOAM TECHNOLOGIES

8 Research & development Manufacturing & processing The engineers at Havel metal foam develop versatile sample constructions for sectors that would like to use aluminium foam as a new material for special applications. They test new alloys for cover sheets, try out different mixtures of the primary materials and develop innovative manufacturing and processing procedures. Furthermore, the following partners offer support for material inspections and tests: Fraunhofer IWU, Technische Hochschule Brandenburg, MPA Dresden, Beschussamt Mellrichstadt. During the production of aluminium foam, infrared ovens a type of powerful toaster are used. Products like aluminium foam sandwiches can be created in particular using the powder metallurgy process. Havel metal foam uses a compacted aluminium powder mixture as baking powder with minimal amounts of titanium hydride (TiH 2 ). The mixture is melted and then broken down. The expanding foam forms a metallic bond with aluminium (AAS, aluminium foam sandwich) or steel (SAS, steel aluminium foam sandwich) cover sheets. The final cooling conserves the foam and provides for extreme stability. Common adhesives are therefore completely omitted. Aluminium foam products are consequently 100%-recyclable and reveal amazing technical characteristics. Even the fire safety properties are only restricted by the melting temperature of the metals being used. All products may be diversely processed afterwards. The cover sheets of aluminium foam sandwiches can be welded, bent and folded using conventional procedures. Drilling, milling or coating products are all possible without any problems. 15 SERIES PRODUCTION

9 Usage areas from A-Z, from automobile construction through interior to civil protection Product solutions Strong structure, light core The core of the Havel Lite products is the extremely light and particularly stable aluminium foam, which is suitable for lightweight constructions with a thickness of around 0.5 g/cm 3. Aluminium foam has amazing properties as a construction material. In particular its extremely light weight, its formability, its reusability and its excellent absorption and conductivity make it an all-rounder with a variety of application possibilities. 17 PRODUCT SOLUTIONS

10 Havel Lite Aluminium foam panels Pure foam plates made of aluminium can be produced starting at a height of a few millimetres. Aluminium foam panels with steel mesh inserts have particularly good tensile strength and are less brittle. However, they are even lighter than sandwiches and are also less expensive than carbon, for example. The cellular structure of the foam allows the material to withstand extreme loads, for example, with the absorption of energy. Havel Lite Sandwiches (SAS and AAS) Aluminium foam can be produced in connection with steel top layers (Havel Lite SAS) or aluminium top layers (Havel Lite AAS) in the form of sandwiches. The bonding of the materials consists completely of metal without any adhesive. This allows the sandwiches to be classified as non-flammable according to DIN EN Simultaneously, customised alloys and coats (paint, marble, wood, wallpaper) are possible. The required mounting points or rails or nuts can be included in the foam or welded (only SAS process). Havel Lite foamed components Foamed components have excellent absorption properties with a simultaneous weight reduction. The foaming of profiles and cavities, also retrospectively, is possible with a thickness tolerance of ± 0.3 to ± 0.8 mm. The vibration dampening properties are advantageous, for example, for quickly moving components from milling machines. The highly absorbing aluminium foam takes away vibrations where necessary and simultaneously allows for higher machining accuracy and speed. Havel Lite 3D shaped elements In principle, almost any geometrical shape can be produced using the powder metallurgy process, just as with moulding processes. The material is not flammable and no smoke is created. A long lifespan as well as its preparation and 100% recyclable properties are additional aspects that make aluminium foam a remarkable, important material. In addition to this are the excellent properties like energy absorption (for example, through plastic deformation in the event of a crash) as well as sound, vibration and oscillation dampening. Completely new industrial solutions for lightweight construction are made possible for sectors like automobile construction, offshore or mechanical engineering. 19 PRODUCT SOLUTIONS Pure aluminium foam plates with a foam skin as an outer layer Welded aluminium foam sandwich plates Foamed steel profiles 3D shaped element Pure aluminium foam with steel mesh improves the strength of the foam Pure aluminium foam plates with inserts SAS production technology: directly foamed bolts and nuts Further processing possibilities: drilling, welding, milling Carriers for mining Foamed aluminium profiles 3D shaped elements from an arm-rest for subway seats 3D shaped element for a shock absorber Panels with a thickness of just 3 mm, for example, are ideal for encasing battery systems Aluminium foam in acrylic Production possibility; bent sandwich Bend test with foamed profiles Foamed steel profiles Aluminium foam crash absorber in the luggage net of an Audi Q7

11 Industry solutions Can be used in the water, in the air and on land The very light and comparably stable aluminium foam is an important material for lightweight constructions in industries and areas where there are high, but cost-effective requirements for the material and at the same time the energy factor should be optimised, for example, through a reduction in weight. Industries Railway industry & infrastructure Protection from explosions, fire and ballistics Automobile construction Ship construction Wind energy Mechanical engineering Offshore Construction Energy technology Aviation & aerospace technology 21 INDUSTRY SOLUTIONS

12 Railway industry and infrastructure The potential savings in energy of up to 30 percent compared to pure steel plates is particularly significant in rail transport. Heavy locomotives are made lighter through the sandwich construction. Less weight means less energy needed to move something. This decreases the energy consumption and increases the efficiency. Less fuel consumption also leads to fewer emissions. Advantages Shell: self-supporting sandwiches Can be formed/welded Can be repaired Saves space / no frames High crash absorption 18 % weight savings Classifications Non-flammable, fulfils fire safety requirement (DIN EN ) No toxic gases (DIN EN ) Achieves fire resistance classes, for example, E30 (DIN EN , DIN EN ) Transport packaging for explosives (UN 6A, 6B, 6C) Can be welded Diverse joint techniques Individual shaping 23 Hood for a fast train (made of shaped and welded aluminium sandwiches) Advantages Buildings, containers and vehicles can be equipped faster, lighter and therefore less expensively through the use of aluminium foam sandwiches. Protection from explosions, fire and ballistics INDUSTRY SOLUTIONS Aluminium + Steel before Aluminium foam after Classification Prevention/ protective measures Minimise terror damage Minimisation of personal and property damage Safety vests & helmets Aluminium foam systems are suitable for usage in personal and building protection. These systems are distinguished by their effect as explosion protection as well as their resistance to fire. Through the cellular structure of the aluminium foam, it is capable to convert large quantities of kinetic energy into deformation energy. Non-flammable (HL3 permit in accordance with EN 45545) Project study: Frauenhofer Institute for Machine Tools and Forming Technology IWU, BlueS, KUKA Systems GmbH, MFPA Leipzig GmbH, Voith Engineering Services GmbH Road & Rail. Application areas Application areas Floor plates with foamed elements (pipes, heating systems, etc.) Ceiling and wall elements Door systems, chairs, tables Toilet enclosures Ramp entrances for wheelchairs Aluminium foam sandwiches in wheel housings (noise reduction) Freight cars SOC equipment Airports Power plants Central registration facilities Embassies, consulates Logistics facilities in critical regions Vehicles e.g. armoured vehicles Security buildings e.g. control centres, police stations Military equipment

13 Automobile construction Advantages Aluminium foam is excellent at absorbing vibrations, blows and hits, which is why it is predestined for usage in rigid and crash-relevant areas. In particular in automobile construction, aluminium foam can be pioneering for carrying structures from personal vehicles and utility vehicles, because it provides higher deformation work compared to pure steel profiles so that the material is first impaired after a very high degree of deformation. Ship construction Advantages High energy absorption in the event of a crash through plastic deformation Bending and compressing behaviour of steel profiles is improved greatly W eight savings Excellent vibration dampening, for example, motor vibrations Weight savings % Hatches, doors, frames and rudders for ships can be manufactured with aluminium foam in the ship construction industry. The foam barely absorbs any water and can be made of alloys that are resistant to seawater. If the ship itself is made of metal foam sandwiches, as is already practised in Finland, more can be transported and the draught lowered with the same energy consumption through the weight reduction of the frame. Lower draught V ibration dampening (for example, drive structure) Reduction of the production expenses (fewer individual components) More load possible I ncrease in torsional stiffness of the complete body by approx. 10 % Can be recycled Reinforcing elements in the body area, for example, Application areas Foamed bumpers Door sills C onnecting areas, joints Roof racks, side members, cross members Lateral protection structure A rea elements, for example, roof bows Elements from a ship s hull Hatches, doors, frames 25 Chimneys Decoration elements Cabins, ceilings, exterior and interior walls Foaming pipe profiles or segments Floor plates Stair elements Structural components (for example, machine and system construction) Cross member 2 A luminium foam crash absorber in the luggage net of an Audi Q7 3 R oof racks 4 Reinforcing elements in the connecting areas 7 5 Door sills 6 Side members Ulives/MARTEC ERA-NET 7 3D shaped element for a guide rail 2 Aluminium foam crash absorber in the luggage net of an Audi Q7 (3D shaped element) 3D shaped element for a shock absorber 7 Pilot project: Ship s hull from a barge Compound AI - AI through MSG process and Al-steel through explosion bonded welded profiles Compound AAS steel through explosion-bonded welded profiles Compound SAS and steel through MSG-process INDUSTRY SOLUTIONS Application areas

14 Wind energy Advantages Aluminium foam or aluminium foam sandwiches can also be used in wind turbines. The weight and therefore drive power can be reduced in turbine blades or guide plates. The savings in significant production expenses in the area of the turbine blades is also a benefit - our aluminium foam shaped elements can already be brought into the desired form during your manufacturing. Weight savings through the replacement of full aluminium through aluminium foam or sandwiches Therefore less drive powers needed Space savings/omission of stabilisation sheets Can be formed, welded, connections possible through threads Girders for spools from a textile machine Foam core enclosed by aluminium Intermediate flange of a gear-cutting machine (with pasted metal foam ring) Cross gantry of a milling machine 27 Advantages Through the use of highly dampening lightweight construction composites, the following advantages are possible depending on the concrete usage: Extreme lightweight construction (30 % weight savings compared with pure aluminium) Higher machining accuracy Higher machining speed Longer lifespan Mechanical engineering The usage of lightweight construction composites allows for significant weight reduction of the masses being moved in mechanical engineering. A lower mass and high vibration dampening are of a great advantage for moving components. Smaller drives and a layout of less powers are possible through this. INDUSTRY SOLUTIONS Application areas Tool machines Electronics production Wood processing Optics production Laser applications Solar module production Micro production Packaging machines Handling and assembly technology Edibles technology Pick & place applications

15 B E L 100% R E C Y C A L Values & properties Nature shows us how it s done. Bones, corals and wood all have a cellular structure with stochastically distributed cavities. This results in high mechanical stability with a simultaneously low weight. And the lightweight metal aluminium also has ideal properties to imitate nature and be even lighter than a massive substance. With 2.7 g/cm³, aluminium has a low density and simultaneously excellent strength. With a density of approximately 0.5 g/cm³, aluminium in a foam form is so light that it even floats in water. Lightweight construction materials with low emissions and energy costs are becoming more and more important in nearly all mobility industries (for example, automobile, ship and aircraft construction). If you would like to combine low weight and mechanical stability, only a few materials come into question, including plastics, carbon fibre reinforced plastic (CFK), glass fibre reinforced plastic (GFK) or wood. Nevertheless, few of these lightweight construction materials are recyclable. 29 VALUES & PROPERTIES Aluminium foam is a very versatile material. Through the natural oxide layer, the metal is extremely light and resistant and can be 100% recycled. Since no adhesives are used, constructions made of aluminium foam are neither flammable nor do they contribute to the fire load. The full potential of the material can be exploited when several of its properties are used in one application. Peel test of a sandwich The aluminium foam enters a metallic bound with the cover top layers.

16 Energy absorption Sound absorption Non-flammable Heat conductivity Aluminium foam is able to absorb effects from pressure and blows and can prevent material destruction (tears, breaks). This increases both the safety and ability to repair the components. 3D shaped element for a shock absorber The sound waves are effectively absorbed when they penetrate the aluminium foam. The density and thickness of the aluminium foam influences the result. Furthermore, clicking properties of components in acoustic systems can be improved significantly. Dampening factor of 25 mm aluminium foam panel, 5 mm aluminium sheet and 3 mm aluminium sheet. Due to the pure metallic aluminium structure (no adhesives or plastics are used), the material is non-flammable. Depending on the alloy, aluminium foam has a temperature resistance of up to 500 C. After 10 minutes 50W/m² heat current Aluminium foam is one of the best metallic heat conductors. This property also makes aluminium foam an excellent heat conductor, which is used in cooling and heating systems. 31 VALUES & PROPERTIES Stress [MPa] Compression (%) Decay - damping factor Eta (-) 1,4E-02 1,2E-02 1,0E-02 8,0E-03 6,0E-03 4,0E-03 2,0E-03 0,0E+00 Frequenzy f [Hz] Fig. 1 Sample before teststing (front) Fig. 3 Sample after teststing (front) FEM-Simulation Compressive strength / compressive yield point: compressive stress where the plateau is reached Aluminium sheet 3mm: 1.9 kg Aluminium sheet 5mm: 3.3 kg Aluminium foam 25mm: 2.0 kg Plateau tension: Average of the compressive stress at 20% and 40% expansion (compression) E-modulus: Increase of relief loop (hysteresis)

17 Material values for sandwiches Unit Steel (S235JR) Aluminium EN-AW 5754 [AlMg3] Aluminium foam sandwich (AAS) Steel Aluminium foam sandwich (SAS) Aluminium foam Description No heat treatment Sandwich Cover layer: Al Core: Al-foam Density g/cm³ (Core) 2.7 (Cover layer) E-modulus N/mm² (Core)* (Cover layer) Sandwich Cover layer: S235JR Core: Al-foam 0.7 (Core) 7.85 (Cover layer) (Core)* (Cover layer) AlSi Poisson ratio Compressive strength 6.000* N/mm² 4 8 (Core)* 13 (Core)* 4 13* Yield strength N/mm² VALUES & PROPERTIES Tensile strength Bending stiffness Thermal conductivity Electrical conductivity Weight x x 10 mm³ N/mm² ** 235 (Cover layer)** 4 6.3** mm/1 000 N ** 2.4** 22 41** W/mK (Core)* 25 (Core)* 12 36* (Cover layer) (Cover layer) S/m 10.0 x x x 10 6 (Core)* 2 4 x 10 6 (Core)* 2 4 x 10 6 (Core)* kg * 21.3* 5 9* Bend test: Comparison of the deflection between steel and SAS For the moment only densities between 0.5 and 0.9 g/cm³ are supplied *Material properties depend on the density; **Material properties depend on the geometry Reference for Calculation: Tabellenbuch Metall. 43. Auflage Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU; All values are calculated and are only an estimation. For specific applications the values have to be verified.

18 Headquarter Consultation & planning Havel metal foam GmbH Am Südtor 1b Brandenburg an der Havel Germany Phone +49 (3381) Fax +49 (3381) Havel metal foam is well-represented throughout the world. We have sales representatives available for you in: Austria, the Czech Republic, Slovakia Erwin Nowak Great Britain Stefan Szyniszewski Poland Heike Uhe Norway, Sweden Leif Bjørge Pedersen 35 CONSULTATION & PLANNING China, Taiwan, Korea Jörg Müller, Jendrick Schäfer Turkey Berrin Baskaya India Sanjay Parmar

19 Research & development FEM calculations Product solutions Series production Further processing Havel metal foam GmbH Am Südtor 1b Brandenburg an der Havel Germany Phone +49 (3381) Fax +49 (3381)

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