Abstract
Interconnected open-cell Al foams, with various fractions of recycled Al alloy scrap, have been produced using a sintering and dissolution process (SDP). The foams are suitable for various functional applications, such as heat exchangers, bone-replacement implants, interconnects, catalyst supports, and sound insulators. Firstly, the NaCl paste was pelletised, by hand, to make spherical balls of approximately 5 mm diameter. The Al alloy scrap was obtained from turning operation in lathe machine. Porous structure was obtained after dissolution of the NaCl balls. The microstructure of Al foams was examined using SEM and EDX. The results show that pores were uniformly distributed along Al matrix and interconnected with surrounding pores. The compressive strength of the foams with small scrap content of 20 wt.% is increased. However, when scrap content is higher, the strength is decreased, as a result of incomplete thermal bonding between Al powder and scrap particle, and excessive oxide content in foam microstructure.
Highlights
Metal foams have attracted many industries, owing to their outstanding properties; such as large energy absorption, high specific strength and stiffness, light weight, large surface area and high damping property [1]
In the sintering and dissolution process (SDP) process, NaCl particle is typically used as space holder material
The major alloying elements of the scraps compose of Si, Fe, Mg, Na and Ca, which is similar to the alloy content of ADC12 alloy
Summary
Metal foams have attracted many industries, owing to their outstanding properties; such as large energy absorption, high specific strength and stiffness, light weight, large surface area and high damping property [1]. There is no prior report of employment of these recycled Al scrap in production of open-cell foams with spherical NaCl. the present research aims to produce opencell Al foams by replacing a conventional Al with recycled Al alloy scrap on the SDP process, with the use of spherical NaCl space holder. The effect of scrap addition at various contents on microstructure and mechanical property of the foams was examined.
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