Porous Al is a lightweight material with excellent heat insulation and sound absorption properties and is expected to be used in a wide range of applications. A method based on mechanochemical reactions has been developed as an environmentally friendly approach to porous Al production. Pure Al powder reacts with pure water to form a coating layer of Al (OH)3 on the surface of the powder particles. Adjacent particles then bind together by adhesion of their coating layers. Since a large number of voids remain between the individual particles, the compact is classified as porous Al. In the present study, a mixture of pure Al powder and pure water was subjected to uniaxial compressive stresses ranging from 0 to 100 MPa to form porous Al. The mechanical properties of the resulting compact were evaluated in terms of the amount of H2 produced, the density, the Al (OH)3 texture, the amount of Al (OH)3 formed, and the results of subsequent compression tests. The density of the porous Al was found to increase with increasing compressive stress during formation. The largest amounts of H2 (800 ml) were produced under a compressive stress of 10 MPa. As the compressive stress was increased, the total amount of generated Al (OH)3 increased, was approximately constant from 30 to 50 MPa, and then decreased. The initial maximum stress, the plateau stress, and the absorbed energy increased with increasing compressive stress and were 100 MPa, 17.5 MPa, and 10.1 MJ/m3, respectively, for a compressive stress of 100 MPa.
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