▎ 摘　　要

NOVELTY - The process includes taking a first interlayer (1) of a cavity structure with complex shape, dividing the inner cavity, forming a supporting bearing area with regular shape and a connecting area (3) with irregular shape, where the shape irregular connecting area in the first interlayer should be continuous without interruption, and there is a flow passage opening (4) ventilating with the outside; cutting the foamed aluminum sample piece (5) according to the support bearing area of the shape rule, and placing the foamed aluminum sample piece in the corresponding position in the first interlayer; and taking the second interlayer matched with the first interlayer, integrally connecting the second interlayer and the first interlayer filled with part of foam aluminum, and forming a complex shape cavity structure. USE - The process is for irregular light high-strength structure foamed aluminum filling, useful e.g. for transportation industry, aerospace industry and building structure industry. ADVANTAGE - The irregular light high-strength structure foamed aluminum filling process solves the problem that the foamed aluminum plate is difficult for secondary process. DETAILED DESCRIPTION - The process comprises taking a first interlayer (1) of a cavity structure with complex shape, dividing the inner cavity, forming a supporting bearing area with regular shape and a connecting area (3) with irregular shape, where the shape irregular connecting area in the first interlayer should be continuous without interruption, and there is a flow passage opening (4) ventilating with the outside; cutting the foamed aluminum sample piece (5) according to the support bearing area of the shape rule, and placing the foamed aluminum sample piece in the corresponding position in the first interlayer; taking the second interlayer matched with the first interlayer, integrally connecting the second interlayer and the first interlayer filled with part of foam aluminum, and forming a complex shape cavity structure; mixing black material, white material, and foaming agent for foaming the polyurethane at 25℃, adding 1-3% iron (Fe), nickel (Ni) magnetic particles, and 0.5-1% graphene, and stirring to prepare foaming raw liquid; taking the complex shape cavity structure as a mold, placing in a preheating furnace, controlling the temperature of the mold at 40℃, vacuumizing the mold cavity, and injecting the foaming raw liquid to the mold by a high pressure injection machine at 14 MPa for all the flow passage ports, which are ventilated to the outside; integrally applying ultrasonic waves, immediately applying a small intensity magnetic field to the supporting bearing area of the shape rule for 3 seconds, applying large intensity uneven magnetic field to the connecting area with irregular shape for 2 seconds, and then applying a magnetic field with the intensity equal to that of the supporting bearing area with regular shape for 1 second; applying uniform pressure of ≮ 10 MPa to the mold cavity, and keeping the pressure for 2 seconds; and closing the pre-heating furnace, ultrasonically processing, quickly releasing pressure so that the mold cavity pressure is equal to the atmospheric pressure, adding baffle to block the flow passage opening, applying variable magnetic field intensity only to the connecting area with the irregular shape at the bottom of the first interlayer, closing other magnetic fields, and normally cooling to room temperature to take out. DESCRIPTION OF DRAWING(S) - The drawing shows a schematic view illustrating the process for irregular light high-strength structure foamed aluminum filling. 1First interlayer 3Connecting area 4Flow passage opening 5Foamed aluminum sample piece 8Limiting foam aluminium