Experimental modelling of copper foams processed through powder metallurgy route using a compressible space holder material

Abstract

The present work is focused on the processing of open cellular copper foams through space holder technique without the use of binders. In this work, moderate pressures were used during the cold compaction of the powders. The main objective was to obtain dense cell walls by limiting the use of binders and use a compressible and lubricant type of space holder material. It has been shown in this study that the use of high compaction pressure helps to decrease/limit the quantity of binder required and this, in turn, yields relatively dense cell walls necessary for better mechanical strength of foams. Using 2N factorial method, mathematical models have been developed to express the final porosity and pore size as functions of the various processing parameters viz compaction pressure, sintering temperature/ time and space holder content. The most significant sintering parameters influencing the porosity and pore size of the processed foams have also been found out.