Friction powder compaction process for fabricating open-celled Cu foam by sintering-dissolution process route using NaCl space holder

Abstract

Open-celled metal foams have received considerable attention in various fields and are expected to be used as engineering materials where heat exchange, sound absorption and filtration are required. In this study, Cu foam specimens with NaCl volume fractions of 60%, 70% and 80% were successfully fabricated by the friction powder compaction (FPC) process with the sintering and dissolution process (SDP) using NaCl as space holders. In the FPC process, no external heat source was used for fabricating Cu foam except for the friction heat generated by the rotating tool plunged into the die and powders. From the X-ray CT and SEM observation of the pore structures of the fabricated Cu foam, it was found that almost the entire specimen had a pore structure similar to the NaCl morphology, regardless of the NaCl volume fraction. This is mainly because the sintering process for Cu particles in the FPC process was achieved at a temperature lower than the melting point of NaCl. From compression tests of the fabricated Cu foam, Cu foam exhibited ductile fracture regardless of its NaCl volume fraction, which is considered to be attributed to the good bonding between Cu particles. The plateau stress and energy absorption decreased with increasing NaCl volume fraction, indicating strong relationships between them. The Cu foam with the highest energy absorption per unit volume up to the specific stress changed from the high-NaCl-volume-fraction Cu foam to the low-NaCl-volume-fraction Cu foam with increasing compression stress. Consequently, it was shown that the mechanical properties of Cu foam can be controlled by adjusting the volume fraction of NaCl.