Open-Cell Aluminum Foams by the Sponge Replication Technique

Abstract

Open-cell aluminum foams were manufactured by a sponge replication technique having a total porosity of ~90%. The influence of the thermal processing conditions such as atmosphere and temperature on the cellular structure, phase composition porosity, thermal conductivity, and compressive strength of the foams was studied. It was found that the thermal processing of aluminum foams in Ar at temperatures up to 800 °C led to aluminum foams with a reduced strut porosity, a lower amount of aluminum oxide, a higher thermal conductivity, and a higher compression strength, compared to foams thermally processed in air. These results were explained by the lower amount of aluminum oxide after thermal processing of the foams.

Determination of Threshold Pressure for Infiltration of NaCl Preforms by a Zinc Base Alloy and its Effect on Young´s Modulus by Numerical Simulation

“…As the capillary law holds (Eq. [1]), this supports the validity of this approach to determine the threshold pressure. From the slope of the fitting line, the work of immersion is computed as r sv À r sl ¼ cCosh ¼ 2:1.…”

“…Eq. [1] shows a linear relationship between the threshold pressure (P th ) and the V p = d p ð1 À V p Þ Â Ã term, with a slope of cCosh. The latter is the work of immersion defined as the free energy change due to the replacement of the solid-vapor interface by the solid-liquid interface (cCosh ¼ r sv À r sl , where r is the interfacial energy) when immersing the solid in the liquid.…”

“…OPEN-CELL metal foams are materials with an optimum combination of mechanical properties such as high specific strength, energy absorption, and electrical/ thermal conductivity among others at minimum weight, whose functionality makes them suited to be used in a wide range of applications. [1,2] An economical and efficient route to fabricate open-cell metal foams is replication processing, which consists of infiltrating liquid metals into porous preforms packed by salt particulates. In this process, salt particulates are commonly used because they are leachable in solvent or water; moreover, the morphology and size of packed particulates can be controlled.…”

Architected porous metals in electrochemical energy storage

“…), which are subsequently removed, for example, by pyrolysis or solvent leaching. Sponge replication method can be viewed as a variation of the previous methods in which metallic powder slurry is impregnated into polymeric foam followed by pyrolysis of polymer and post-sintering [6]. Dealloying, a corrosion process in which one or several components of an alloy are dissolved, is a powerful method of fabrication of metal foams and sponges capable of producing micro-, nano-and hierarchical (micro-nano) pores [13,27,28].…”

Ni/Al-Hybrid Cellular Foams: An Interface Study by Combination of 3D-Phase Morphology Imaging, Microbeam Fracture Mechanics and In Situ Synchrotron Stress Analysis

“…Al alloy foams (AlSi 7 Mg 0 • 3) produced by investment casting based on a template analogous to [38] with a pore size of about 10 ppi manufacturer information were purchased from Celltec Materials GmbH (Dresden, Germany) and coated with a hard facing Ni layer using electrodeposition [12,13] with a coating thickness of about 50 µm. For the electrodeposition a commercial Ni sulfamate electrolyte at a pH of 3.8 and a temperature of 40 • C was used as described by Jung et al [12].…”