Abstract
An indirect rapid prototyping method to fabricate ordered porous aluminum was carried out by combining the selective laser sintering and the infiltration casting. The preforms were designed by Pro/Engineer and fabricated by the selective laser sintering with the resin-coated sand. The aim of structure design and control for ordered porous aluminum was achieved. Meanwhile, the structure and mechanical property characterization of the ordered porous aluminum were studied. The results indicated that the specimens had higher porosity than the original models. The deviation appeared and accumulated mainly ascribing to the dimension variation between the sand preform and the preform model. The identical tendency of geometry variations could be utilized to revise the original model in order to compensate the dimension variation. The compressive stress-strain curves of the ordered porous aluminum for pure specimens showed the typical feature of porous materials and increased smoothly and continuously while ZL111 specimens had some peaks and drastically varied plateau regions. The infiltration temperature had an obvious effect on the compressive property for ZL111 specimens compared with pure aluminum specimens. The optimized structure and strengthened matrix made the ZL111 specimen had highest compressive strength 86.48 MPa and excellent energy absorption capacity in this study.
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