Abstract

Friction stir incremental forming (FSIF) process was applied to join a metallic foam with a resin sheet for fabrication of porous metal–nonporous resin composite. In this process, a rotating rod-shaped tool was vertically pushed and horizontally fed against the sheet on the foam. The sheet was frictionally heated and incrementally deformed by the rotating tool, while the cellular matrix of the foam was not plastically deformed. The bottom of the sheet was mechanically interlocked to the pores of the foam by plastic flow of the frictionally heated sheet. In this study, (1) the joining characteristics of an open-cell type nickel foam and a polymethyl methacrylate (PMMA) sheet and (2) the compressive characteristics of the nickel foam/PMMA sheet specimen were introduced.

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