Abstract
The present paper describes the manufacturing process of open-pore metal foams by investment casting and the mesostructural/morphological evolution resulting from a new technique of modifying the precursor. By this technique, the precursor is coated with a polymer layer whereby a thickening of the struts occurs. Relative densities in the range of1.85≤ρrel≤25%of open-pore metal foams can be achieved with high accuracy. The samples investigated have pore densities ofρP=7 ppi, 10 ppi, and 13 ppi. The relevant processing parameters needed for a homogenous formation of the polymer layer are determined for two different coating materials and the resulting open-pore foam’s mesostructure is characterized qualitatively and quantitatively. The alloy used for investment casting open-pore metal foamsis AlZn11. The microstructural evolution of these foams is evaluated as a function of the mesostructure. Differences in the microstructure are observed for foams with low and high relative densities and discussed in terms of cooling subsequent to investment casting.
Highlights
Open-pore metal foams possess attractive properties due to their highly porous and light weight structure in combination with their base material
The present paper describes the manufacturing process of open-pore metal foams by investment casting and the mesostructural/morphological evolution resulting from a new technique of modifying the precursor
The method used in this investigation is a modified investment casting process which offers great advantages due to a targeted adaptation/tailoring of the relative density ρrel, structure of the cells, geometry, and alloy composition for any specific application
Summary
Open-pore metal foams possess attractive properties due to their highly porous and light weight structure in combination with their base material. This group of materials is of great interest for different fields of application, such as in the sectors of heat engineering [1, 2], biomedical engineering [3, 4], electrical energy storage [5, 6], or lightweight design [7, 8]. Thickening the struts can just be conducted within narrow confines For these reasons an alternative method for a mesostructural design of open-pore metal foams is developed. Using this method any required relative density ρrel can be achieved through a homogenous thickening of the struts. The microstructural evolution resulting in the investment casted open-pore metal foams is identified
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