Production of Open-Cell Foam Using Additive Manufacturing Method and Porous Morphology Effects

In recent years, metal foams have emerged as the most advanced materials for structural, thermal, and sound insulation purposes. Metal foams have more exciting properties than other lightweight materials, such as higher deformation resistance, compressive strength, and crashworthiness. This review article highlights various conventional and non-conventional manufacturing methods of metal foams under direct and indirect foaming techniques. Non-conventional methods of metal foam fabrication, such as additive manufacturing, novel methods, and metal syntactic foaming have been described in detail. A detailed review of foaming agents, space holders, and filler particles utilised in the metal foaming process is provided. Recent advancements in the metal foam coating process and coating materials have also been discussed. GRAPHICAL ABSTRACT

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“…The produced copper foam finds its application in electrodes, filters, heat exchangers, etc. Mustapha et al [42] Nylon powder and plastic acid.…”

Section: Uv-pulsed Laser Deposition Additive Manufacturing(am)mentioning

confidence: 99%

Fabrication methods and property analysis of metal foams – a technical overview

Nawaz

Rani

2023

Materials Science and Technology

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“…As 3D printing technology continues to advance, the production of porous materials could have more design freedom [3]. Despite the ease of production using 3D printing technology as an alternative to traditional methods, controlling the porosity and pore size of porous materials can be challenging as it heavily relies on the printing process and material used, which can impact the surface finish and porous structure [4]. Thus, the surface finish of 3D printed objects, and the necessary post-processing for a smooth and high-quality finish are also important when introducing the new generation of opencell foam.…”

Section: Introductionmentioning

confidence: 99%

Permeability of 3D Printed Open-Cell Foam Produced Using Selective Laser Sintering

Anuar,

Saat,

Mohd Zini

et al. 2023

KEM

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3D printing technology has gained popularity among researchers since it can produce complex geometries, such as open-cell foam. The open-cell foam shows potential in a range of applications such as energy absorption, thermal management, filtering, and acoustic damping. However, the feasibility of the applications depends on the material used to construct the 3D printed open-cell foam and its physical properties e.g, pore size and porosity. Therefore, understanding the physical properties is crucial in classifying this new generation of open-cell foams. This study aims to determine the permeability of 3D printed foams using the Forchheimer equation and compared the results with a fractional estimation method to reduce the duration of future experiments. The fractional results were validated through computational fluid dynamics (CFD) simulations. The result shows that the proposed estimation method can be used to determine the permeability of 3D printed foam with a height of 60 mm or larger, and up to six times larger than 5 PPI (pores per inch). However, it is recommended to conduct simulations of large pore size foam using a 3D model to accurately describe the local velocities in the free stream region.

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Mechanical Properties and Deformation Behavior of Open-Cell Type Aluminum Foams with Structural Conditions and Alloy Composition

Kim,

Ha,

Lee

et al. 2024

Metals

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Open-cell type aluminum foams with various structural conditions and alloy compositions were manufactured using the replication casting process. The porosity of the foams ranged from 55% to 62%, with pore sizes of 0.7~1.0 mm, 1.0~2.0 mm, and 2.8~3.4 mm. The alloys employed included commercial A356 and A383, as well as Al-6Mg-(0, 2, 4, 6)Si alloys. Compression tests were conducted under various conditions of the foams, and the results were comparatively analyzed based on the detailed structural conditions and alloy compositions. It was observed that for the same alloy composition and equivalent porosity, a reduction in pore size led to an increased number of cell walls, enhancing energy dispersion and resulting in higher compressive yield strength and energy absorption. Under the same pore size, a decrease in porosity increased the relative density and cell wall thickness, leading to improved compressive yield strength and energy absorption. Furthermore, compressive evaluation based on alloy composition revealed the influence of the inherent mechanical properties of the material on the mechanical properties of open-cell type aluminum foams. Specifically, it was confirmed that alloys with higher ductility exhibited elastic behavior of the internal cells under external stress, significantly influencing the energy absorption of foams.

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Production of Open-Cell Foam Using Additive Manufacturing Method and Porous Morphology Effects

Cited by 3 publications

References 5 publications

Fabrication methods and property analysis of metal foams – a technical overview

Fabrication methods and property analysis of metal foams – a technical overview

Permeability of 3D Printed Open-Cell Foam Produced Using Selective Laser Sintering

Mechanical Properties and Deformation Behavior of Open-Cell Type Aluminum Foams with Structural Conditions and Alloy Composition

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