Selected Microstructural and Mechanical Properties of Open-Cell Metal Foams

Abstract

The microstructure and mechanical properties of open-cell metal foams have long been studied from various angles. The materials discussed in this paper were fabricated using an unconventional sintering method and their properties are unique. An important part of the process is reduction of Fe(III) oxide, acting as a foaming agent and a space holder. Four powder mixtures were analysed: ASC100.29, ASC100.29 + C, DISTALOY SE and DISTALOY SE + C. The aim of the tests, performed with a specially developed setup, was to determine the impact energy absorption capacity of the Fe-based foams. From the results, it is clear that the metal foams can be used in many applications, including lightweight structures, filters, heat exchangers and energy-absorbing systems. Keywords: open-cell metal foams, Fe-based foams, reduction of metal oxides, space holder technique, energy dissipation Highlights • The Fe-based metal foams were produced through sintering, which is an efficient and cost-effective process. • The reduction of Fe (III) oxide by hydrogen and the addition of Cu were responsible for a uniform structure and open porosity. The average pore diameter did not exceed 100 µm; the porosity ranged from 67.9 % to 80.3 %, depending on the powder mixture composition. • The motion of the hammer striking the material was monitored using a time-lapse camera. • The Fe-based foams seem suitable for lightweight structures, energy-dissipating and energy-absorbing systems, filters, catalytic converters, and heat exchangers.