Review: Closed-Cell Metallic Foams Produced via Powder Metallurgy

Behymer, Nathan; Morsi, K.

doi:10.3390/met13050959

Cited by 9 publications

(5 citation statements)

References 151 publications

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“…With regard to the foaming process, heating and cooling rates have an important effect on the foaming process. Insufficient heating rates during foaming, <1 K/s, may cause cracks in the precursor and gas loss [94], while at higher heating rates, the precursor might not be heated uniformly, resulting in inhomogeneous foaming [95]. During the cooling process, increasing the cool-ing rate (>2.5 K/s) can mitigate drainage and bubble coalescence and reduce the number of defects in the cell wall.…”

Section: Powder Metallurgy Foaming Methodsmentioning

confidence: 99%

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Fu,

2024

Materials

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Closed-cell aluminum foams have many excellent properties, such as low density, high specific strength, great energy absorption, good sound absorption, electromagnetic shielding, heat and flame insulation, etc. As a new kind of material, closed-cell aluminum foams have been used in lightweight structures, traffic collision protections, sound absorption walls, building decorations, and many other places. In this paper, the recent progress of closed-cell aluminum foams, on fabrication techniques, including the melt foaming method, gas injection foaming method, and powder metallurgy foaming method, and on processing techniques, including powder metallurgy foaming process, two-step foaming process, cast foaming process, gas injection foaming process, mold pressing process, and integral foaming process, are summarized. Properties and applications of closed-cell aluminum foams are discussed based on the mechanical properties and physical properties separately. Special focuses are made on the newly developed cast-forming process for complex 3D parts and the improvement of mechanical properties by the development of small pore size foam fabrication and modification of cell wall microstructures.

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Section: Powder Metallurgy Foaming Methodsmentioning

confidence: 99%

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Fu,

2024

Materials

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“…The properties of the porous metal vary depending on their pore size, pore orientation, and porosity [1,2]. Porous metals with closed pores exhibit high compressive strength, stiffness, buoyancy, and impact absorption [3]. On the other hand, porous metals with open pores have a high specific surface area and permeability [4].…”

Section: Introductionmentioning

confidence: 99%

“…Metal fibers typically possess about 60% porosity, and ultrafine fibers need to be used to filter fine particles, which can be very expensive [19]. On the other hand, metal powder sintered materials can have a wide range of particle sizes, from fine to large particles, and allow the fabrication of metal filters with complex pore structures through the use of foaming agents, particle size control, heat treatment or coating, and heating rate control [3,[20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Pore Characteristics of a Double-Layered Pore Structure Powder Filter Fabricated by the WPS Process

Lee,

Kim,

Kang

et al. 2024

Metals

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In order to supply high-purity process gas in the semiconductor manufacturing process, a gas filter is used to remove particles that may be contained in the gas. However, because the gas filters currently in use have simple pore structures, there is a need to increase filtration efficiency through the development of filters with complex pore structures. In this study, a metal powder filter with double-layered pores was manufactured using a Wet Powder Spraying process (WPS) to increase the filtering efficiency of gas filters used in semiconductor manufacturing. The effects of the mixing ratio of spherical-shape and flake-shape powders and the rolling process on the filter’s characteristics were investigated. The filter’s performance, microstructure, and surface roughness were evaluated by measuring porosity and gas permeability. The results showed that as the ratio of flake-shaped powder decreased, the thickness of the coating layer and the porosity of the filter decreased. Additionally, it was observed that as the rolling process progressed, the non-uniform pore structure was oriented parallel to the cross-section of the filter regardless of the mixing ratio. Measurements found that the gas permeability of the uncoated filter support was the highest, and that gas permeability decreased as the proportion of spherical powder increased regardless of the average particle size of the mixed powder. Lower gas permeability was observed in rolled samples. A filtration efficiency of LRV 3 or higher was confirmed.

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“…Interest in metallic foams has significantly grown over the past few decades, largely due to their unique physical and mechanical properties [1][2][3][4]. Such properties include a high internal specific surface area (for open-cell foams), a high stiffness-to-weight ratio, a high strength-weight ratio, and an ability to absorb sound and energy [5][6][7][8][9][10][11].…”

Section: Introductionmentioning

confidence: 99%

“…Aluminum (Al)/Al alloy foams are the most studied metallic foams, both as open-cell foams [12,13] and closed-cell foams [14,15]. The production of closed cell aluminum foams has been limited to two main approaches, the melt route [16] and the powder metallurgy (PM) route [17]; the latter has recently been reviewed by one of the authors [4]. In the PM route, aluminum powders are mixed with a blowing agent powder (i.e., a gas-releasing powder, such as titanium hydride (TiH 2 ) [18]) and compacted to form a highly dense "bulk" foamable precursor [19].…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Uniform and Rounded Closed-Cell Aluminum Foams Using Novel Foamable Precursor Particles (FPPs)

Mudge,

Morsi

2024

Metals

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The powder metallurgy (PM) route for the production of closed-cell metallic foams has recently received a significant amount of attention. One of the major issues is the non-uniform and non-spherical nature of the cells produced, which can negatively affect the mechanical behavior. The current paper uses the PM route to process metallic foams for the first time using novel Al-TiH2 foamable precursor “particles” (FPPs). The effect of FPP content (0–10 wt.%) on the developed foam structure of aluminum and its mechanical properties is investigated. An increase in FPP content results in a decline in product density by forming uniform and near-spherical cells. The main advantage of the FPPs is the localization of the blowing agent TiH2 particle content within Al-TiH2 composite particles (i.e., giving rise to a higher local TiH2 content), which has led to the production of pores with relatively high circularities even at very low overall TiH2 contents. The foams produced displayed energy absorption capacities of 10–25 MJ/m3 at 50% strain, and maximum energy absorption efficiencies ranging from 0.6–0.7 (for 40–60% closed cell content)

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Review: Closed-Cell Metallic Foams Produced via Powder Metallurgy

Cited by 9 publications

References 151 publications

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Fabrication, Processing, Properties, and Applications of Closed-Cell Aluminum Foams: A Review

Microstructure and Pore Characteristics of a Double-Layered Pore Structure Powder Filter Fabricated by the WPS Process

Fabrication of Uniform and Rounded Closed-Cell Aluminum Foams Using Novel Foamable Precursor Particles (FPPs)

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