Aluminum metal foam has become an advanced popular material because it has excellent mechanical and electrical properties and is lightweight. The present work developed the Aluminium metal foam specimen using wax powder as a blowing agent through the powder metallurgy method. The effect of process parameters such as powder size, stirring speed, sintering temperature, and foaming agent content on the mechanical behavior of the developed specimens has been studied experimentally. In the design of experiments, the Taguchi orthogonal L9 array has been implemented. The percentage of Porosity was estimated using the Archimedes principle, and mechanical behaviors such as flexural, tensile, and compressive strength were determined. The ANOVA analysis of variance it's been carried out to check the significant parameters affecting the mechanical behavior of developed specimens. It was observed that the powder size is the highly significant parameter, followed by stirring speed, the content of the foaming agent, and sintering temperature. The Maximum Porosity 71.30%, Compresssion strength 12.01MPa, Tensile strength 6.16 MPa, Flexural strength 5.18 MPa. The microstructure study reveals that there is no any adequet compostion in the specimen. The novelty in this research work is using a novel foaming agent as a Wax powder to develop aluminium metal foam and attained good properties.
Research Article
Effect of Influencing Parameters on Developing Aluminium Metal Foam by using Powder metallurgy technique with foaming agent as a Wax Powder
https://doi.org/10.21203/rs.3.rs-2131435/v1
This work is licensed under a CC BY 4.0 License
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Aluminium metal foam
Wax powder
Powder Metallurgy
Porosity
Mechanical properties
Taguchi
Aluminum metal foam has been widely used in aerospace, automotive components, civil engineering, renewable energy field, and biomedical implants due to its lightweight and good mechanical properties [1, 2]. The metallic foam has a porous composite structure due to which it possesses excellent strength to weight, ideal thermal, sound, acoustic insulation, and superior impact energy absorption [3–5], heat insulation [6] electromagnetic shielding [7]. There are several techniques to produce metal foam ranging from liquid to solid route like direct foaming, space holder, ball making, and casting for the Aluminium metal foam. The powder metallurgy technique is the best process to achieve uniform pores structure over the specimen in the case of open or closed cells [8–10]. The high-temperature fabricated composite reveals the foam with a stable and homogeneous distribution. They investigated the effects of changes in structural characteristics of foam density on their mechanical properties. In another study, the Aluminium metal foams were developed through Aluminium powder Carbamide as a space holder route. They studied the effects of variation in compressive behavior of Aluminium foam of relative density, size, and pore shape [11–13]. The fabrication techniques have their mechanical, thermal, and acoustic properties and potential applications [14–18].
The literature study shows that Bouwhuis et al. investigated the mechanical behavior, and failure analysis observed that electrodeposited nanocrystalline Ni reinforced in uniaxial compression of Aluminium metal foam. Ni foam with hollow nanocrystalline tube behavior is predicted in cellular composite material [19]. Brown et al. developed composite metal foams (CMFs) using water-cooled, air-casting, and powder metallurgy methods. The performance of developed CMFs was studied under a bending test during loading with in-situ acoustic emission analysis [20–21]. The AFs were produced with different pore densities. The flexural strength and stiffness of the prepared samples were examined. The study's finding shows that composite was found to decrease in pore size with higher stiffness. The increase in the composites' stiffness was found with a decrease in pore size. The non-destructive and mechanical tests were performed to estimate the metal foams' properties accurately [22]. Kim et al. developed a mathematical correlation various in AF's compressive properties and electrical conductivity [23]. Kadkhodapour and Raeisi investigated the relative density of mechanical behavior of closed porous cell AF using a numerical method. The obtained results were analyzed with analytical and experimental results [24]. Jung and Diebels reviewed the different micromechanical characterization techniques for the metal foams and reported their usage in various applications [25]. Jung et al. developed a micro-tensile test setup for AF and hybrid Ni/Al foams to investigate the stress-strain curves [26–27]. The test results reveal that different material behavior such as hardening plastic behavior, young modulus, and fracture behavior can be studied from the obtained stress and strain relationship. Duarte and Ferreira reported the various micro-size reinforcements to improve the mechanical behavior of open metal porous cells and closed metal porous cell Aluminium metal foams [28]. García et. al. reviewed the different production processes of metal foams, their properties, and their commercial applications [29]. Orbulov and Szlancsik evaluated the mechanical behavior of metal matrix syntactic foams with the Aluminium matrix. In addition, fatigue properties and toughness of MMSFs have been assessed [30]. Shunmugasamy and Mansoor investigated the compressive behavior of open-cell 6101 AF in as-cast and as-rolled conditions [31]. ] Nawaz and Rani fabricated Aluminium alloy 6063 foam and evaluated their percent porosity and density using the Archimedes principle [32]. Liu et. Al. proposed a novel method for assessing the surface area of the metal foam porous region with mathematical co-relation between the porosity and pore diameter [33]. The developed mathematical model helps to predict the required data precisely. Aluminum metal foam's closed cell static behavior in shear and tension was studied to determine their mechanical behavior and failure analysis modes [34–38]. Ali et al. manufactured the hybrid closed-cell AF and investigated the effect of the different parameters, such as temperature and wt. % foaming agent and mixing speed on the porous area and pore size using the Taguchi DOE approach [39, 40]. The study shows that amount of the foaming agent is the highly significant factor, followed by stirring speed and temperature. In another study, the AFs were produced by the powder metallurgy method with Titanium hydride, TiH2 as a foaming agent. A multi-objective optimization approach studied the effect of foaming agent content, compaction pressure, and temperature [41]. Arif et al. fabricated the aluminum foams reinforced with silicon carbide and carbon nanotubes using a powder metallurgy approach. The aluminum alloy in powder form was used as the matrix material, titanium hydride (TiH2) powder was used as a foaming agent, and silicon carbide (SiC) particles and carbon nanotubes (CNTs) were used as reinforcing elements [43]. The test results show that the CNT and SiC particles significantly affected the elastic-plastic deformation behavior of the precursor materials. Further, Ding et al. reported a new method for optimizing the cellular structure of alloy foams by pretreating TiH2 with a layer of powder. They observed that TiH2 was completely encapsulated in the molten Sn at an early stage of foaming when the matrix alloy was still solid. This assists in capturing the liberated H2 when TiH2 begins to decompose. Eventually, this helps to avoid cracks in the solid matrix by enhancing the utilization ratio of TiH2 as a blowing agent [44]. Geramipour and Oveisi [45] produced semi-open-cell aluminum foams with CaCO3 as a foaming agent using a powder compact melting process. They studied the effects of various parameters such as precursor compaction pressure, foaming agent content, temperature, and time of the foaming process on the cell microstructure, linear expansion, relative density, and compressive properties of the foam.
The literature study confirmed that Metal foam has broad applications, but it is still not used widely. The main challenging task is to achieve a good percentage of Porosity in the prepared specimen with uniform integrity structure over the entire sample. Parafin Wax powder (CnH2n+2) foaming agent used because during powder metallurgy process the porosity is developes as the H2 liberated [44] paraffin wax powder it has maximum hydrogen chemical composition content. Hence, in the present work, the Aluminium metal foam is developed through a powder metallurgy approach using wax powder as a foaming agent to achieve good Porosity and uniform structure. Taguchi DOE approach is followed to investigate the effect of various input process parameters on the mechanical behavior of the developed AFM samples. Eventually, variance analysis (ANOVA) was implemented to know the significant and essential factors affecting output properties.
2.1 Preparation of specimen of Aluminium metal foam
The Aluminium Metal Foam (AMF) specimens were prepared with a powder metallurgy approach the detail process parameters as shown in fig 1. The Aluminium (6061) was selected as the base powder and the wax as a foaming agent; both powders are prepared in sufficient size using a ball milling machine. Then these powders are correctly blended with stirring speed for 10 minutes. The specimens were compacted with a UTM machine by applying a 30 KN load so that both powders were closely packed with a cold compaction process. Then the samples were sintered for 30 minutes using an electric furnace. AA60061 metal powders supplied from M/s Metal Powder Company Ltd Tamil Nadu, India, were used as the base metal for producing metal foams. Foaming agents (wax powder supplied by LOBA Chemical, India).
The morphology of the fabricated AMF was characterized by using the SEM. The phase structure of AFM is investigated using the X-ray diffraction method. Make- Bruker D8 Inc, Germany, with a source (λ Ό 1.5406 Å) Cu Kα radiation. The XRD pattern was recorded at a scanning rate of 1° per minute and 2θ range from 20° to 80° with a step size of 0.02°. The compressive tensile and flexural strength of all fabricated AMF specimens was investigated using a UTM per the ASTM standard.
The density and percentage of Porosity of the prepared specimens were measured using Archimedes' principal, as reported by Nawaz and Rani [32]. Density and Porosity have been calculated as per the below equations. The measured density and percentage of Porosity of the prepared specimens are listed in Table 1.
Table 1
(%) porosity of the various AMF specimens
|
Specimen No. |
Initial vol. of water in Measuring Jar(MJ) in cc |
Final vol. of water in Measuring Jar(MJ) in cc |
Actual vol. of foam in cc |
Mass of specimen in g |
Density of Foam in g/cc |
Density of Aluminium (6061) in g/cc |
Porosity (%) |
|
1 |
500 |
566 |
66 |
58 |
0.88 |
2.7 |
67.45 |
|
2 |
500 |
568 |
68 |
60 |
0.88 |
2.7 |
67.32 |
|
3 |
500 |
570 |
70 |
62 |
0.89 |
2.7 |
67.20 |
|
4 |
500 |
576 |
76 |
61 |
0.80 |
2.7 |
70.27 |
|
5 |
500 |
583 |
83 |
65 |
0.78 |
2.7 |
71.00 |
|
6 |
500 |
593 |
93 |
73 |
0.78 |
2.7 |
70.93 |
|
7 |
500 |
581 |
81 |
65 |
0.80 |
2.7 |
70.28 |
|
8 |
500 |
589 |
89 |
70 |
0.79 |
2.7 |
70.87 |
|
9 |
500 |
602 |
102 |
79 |
0.77 |
2.7 |
71.31 |
2.2 Determination of mechanical properties of the prepared specimens
The mechanical properties like flexural, tensile, and compressive strengths have been determined using a computerized UTM with a speed of 2mm/min and room temperature of 30 oC. The specimens before and after the test, along with the experimental details are shown in figure 4, 5, and 6. The measured mechanical properties are listed in table 3.
2.3 Taguchi approach
Design of experiment, Taguchi is the most famous statistical tool used to optimize the process for different parameters. It helps to minimize the number of experiments compared to the conventional experimental approach. This eventually helps to reduce the cost and time incurred in the traditional practical approach [42]. The conventional experimental approach considers a single factor by changing one variable instantly, keeping others constant. The primary limitation of this conventional method may exclude any feasible of its interactions among the specified set of different parameters. The secondary drawback is that it will not be able to analyze the effect in a single experiment on all the factors and investigate their main effects. It has been observed that these limitations can be overcome by employing the Taguchi technique. The Taguchi approach estimates the output using the response function mean value for a set of defined parameters. It also helps analyze and optimize the proper possible combinations in its input process parameters, giving the best output responses. The Taguchi approach will help transform the experimental data to signal a noise ratio. Various S/N ratios exist as per the required type of its characteristics. The present work employs a significantly better signal to noised S/N ratio for all the output parameters. The S/N signal-to-noise ratio is evaluated with a logarithmic transformation of the loss function [37].
Where y is the observed data & n is the total number of observations
The four input process parameters used in the recent study, with their three levels, are listed in Table 2.
Table 2
Input process parameters along with their levels for the Taguchi approach
|
Input process parameters |
Levels |
||
|
1 |
2 |
3 |
|
|
A: Powder size (µm) |
140 |
120 |
100 |
|
B: Stirring speed (rpm) |
1400 |
1200 |
1000 |
|
C: Sintering temperature (oC) |
500 |
400 |
300 |
|
D: Content of foaming agent (wt. %) |
3 |
6 |
9 |
The experimental runs were performed as mentioned in Table 3. the % contribution of the test parameters was investigated using the ANOVA technique. The mean and combined response characteristic curves are plotted using Minitab-17 software [42].
Table 3. Standard L9 orthogonal array for Design of Experiment
|
L9 Exp. run |
A Powder size (µm) |
B Stirring speed (rpm) |
C Sintering temp. (°C) |
D Content of foaming agent (wt. %) |
Porosity (%) porosity |
Compressive Strength (MPa) |
Tensile Strength (MPa) |
Flexural Strength(MPa) |
|
1 |
140 |
1400 |
500 |
3 |
67.45 |
12.01 |
6.16 |
5.18 |
|
2 |
140 |
1200 |
400 |
6 |
67.32 |
11.51 |
5.17 |
4.82 |
|
3 |
140 |
1000 |
300 |
9 |
67.20 |
11.01 |
4.78 |
4.55 |
|
4 |
120 |
1400 |
400 |
9 |
70.27 |
10.51 |
4.48 |
5.05 |
|
5 |
120 |
1200 |
300 |
3 |
71.00 |
10.01 |
4.08 |
4.58 |
|
6 |
120 |
1000 |
500 |
6 |
70.93 |
9.51 |
3.98 |
4.48 |
|
7 |
100 |
1400 |
300 |
6 |
70.28 |
9.01 |
3.89 |
4.69 |
|
8 |
100 |
1200 |
500 |
9 |
70.87 |
8.51 |
3.81 |
3.90 |
|
9 |
100 |
1000 |
400 |
3 |
71.31 |
8.20 |
3.74 |
3.80 |
The morphological investigation of fabricated AMF (for sample 9 reported in Table 3) was performed using SEM and depicted as shown in Fig. 7 (a-b). It shows that the homogeneous porous nature resulted from the dissolution of wax powder during the sintering process in the powder metallurgy technique.
The EDS analysis for the above reported AMF sample is depicted in figure 8. The dark gray matrix phase is composed of (Al-Fe-Si). The other elemental compounds observed through EDS spectra are C, O, Mg, Ca, and Ti. The details of the EDS spectra value considered in weight and the atomic percentage are shown in table 4.
Table 4. The elemental composition present in AMF specimen
|
Element |
Weight % |
Atomic % |
|
C |
24.76 |
40.89 |
|
O |
9.83 |
12.18 |
|
Mg |
0.66 |
0.53 |
|
Al |
60.04 |
44.13 |
|
Si |
0.47 |
0.33 |
|
Ca |
3.01 |
1.49 |
|
Ti |
0.13 |
0.05 |
|
Fe |
1.09 |
0.39 |
An X-ray Diffraction (XRD) study shows the crystallographic phases within the prepared specimen (for sample 9 reported in Table 3). This XRD technique is carried out at room temperature, and it gives evidence that the prepared specimen with a foaming agent as a wax powder (C3H6O3) shows the highest peak at 38 degrees, as shown in figure 9.
The effect of various input process parameters like powder size, sintering speed, sintering temperature, and foaming agent content on the mechanical properties of the developed AMF like porosity (%), compressive, tensile, and flexural strengths using the Taguchi DOE approach is discussed in below section.
3.1 Effects of factors and ANOVA
3.1.1 Effects of process factors on Porosity %
The data acquired using DOE L9 orthogonal array for output parameters, i.e., porosity (%), compressive, tensile, and flexural strengths, are transformed into S/N ratios listed in Table 5, 6, 7 8, respectively. The significant factor's percentage (%) contribution is reported by ANOVA analysis for the respective output properties. The percentage contribution of significant factors on the % porosity is reported in ANOVA table 5.
Table 5. ANOVA results for Porosity (%)
|
Source |
DOF |
Adj. SS |
Adj. MS |
F-Value |
P-Value |
Percentage of contribution |
|
A |
1 |
18.3568 |
18.3568 |
13.06 |
0.022 |
74.14 |
|
B |
1 |
0.3427 |
0.3427 |
0.24 |
0.647 |
1.38 |
|
C |
1 |
0.1014 |
0.1014 |
0.07 |
0.801 |
0.41 |
|
D |
1 |
0.3377 |
0.3377 |
0.24 |
0.650 |
1.36 |
|
Error |
4 |
5.6208 |
1.4052 |
|
|
22.70 |
|
Total |
8 |
24.7594 |
|
|
|
|
The ANOVA results showed that powder size significantly affects % porosity (p = 74.14%), followed by sintering speed (p = 1.38%), wt. % of foaming agent (p = 1.36%), and sintering temperature (p = 0.41%) depicted minimum important and significant contributions to % porosity. The main and interaction plots depict individuals and affect their interaction on % porosity, as shown in figure 10.
3.1.2 Effects of process factors on compressive strength
The percentage contribution of significant factors to the compressive strength is reported in ANOVA table 5. For compressive strength, it was observed that powder size has a significant influence (p = 85.02%), followed by wt. % of foaming agent (p = 81.20%), sintering speed (p = 8.58%) and sintering temperature (p= 0.96%) depicted least significant contributions to compressive strength. The main plot and interaction plot depicts individuals and their interaction effects on compressive behavior, as shown in figure 11.
Table 6. ANOVA results for Compressive Strength (MPa)
|
Source |
DOF |
Adj. SS |
Adj. MS |
F-Value |
P-Value |
Percentage of contribution |
|
A |
1 |
16.6001 |
16.6001 |
113.27 |
0.000 |
85.02 |
|
B |
1 |
1.6748 |
1.6748 |
11.43 |
0.028 |
8.58 |
|
C |
1 |
0.1873 |
0.1873 |
1.28 |
0.321 |
0.96 |
|
D |
1 |
0.4760 |
0.4760 |
3.25 |
0.146 |
81.20 |
|
Error |
4 |
0.5862 |
0.1465 |
|
|
3.00 |
|
Total |
8 |
19.5244 |
|
|
|
|
3.1.3 Effects of process factors on tensile strength
The % contribution of significant factors to the tensile strength is reported in ANOVA table 6. For tensile strength, it was observed that powder size has the greatest influence (p = 70.69%), afterwords by sintering speed (p = 13.38%), sintering temperature (p = 4.69%), and wt. % of foaming agent (p = 2.70%) depicted least significant contributions to tensile strength. The main and interaction plots depict individuals and their effects on tensile strength, as shown in figure 12.
Table 7. ANOVA results for Tensile Strength (MPa)
|
Source |
DOF |
Adj. SS |
Adj. MS |
F-Value |
P-Value |
Percentage of contribution |
|
A |
1 |
3.6452 |
3.6452 |
33.16 |
0.005 |
70.69 |
|
B |
1 |
0.6902 |
0.6902 |
6.28 |
0.066 |
13.38 |
|
C |
1 |
0.2420 |
0.2420 |
2.20 |
0.212 |
4.69 |
|
D |
1 |
0.1395 |
0.1395 |
1.27 |
0.323 |
2.70 |
|
Error |
4 |
0.4397 |
0.1099 |
|
|
8.53 |
|
Total |
8 |
5.1567 |
|
|
|
|
3.1.4 Effects of process factors on Flexural strength
The % contribution of significant factors to the flexural strength is reported in ANOVA table 7. For flexural strength, it was observed that, powder size has the highest influence (p = 44.92%), afterword’s by sintering speed (p = 42.09%), sintering temperature (p = 0.68%) and wt. % of foaming agent (p = 0.03%) depicted least significant contributions to flexural strength. The main and interaction plot depicts individuals and their effects on flexural strength, as shown in figure 13.
Table 8. ANOVA results for Flexural Strength (MPa)
|
Source |
DOF |
Adj. SS |
Adj. MS |
F-Value |
P-Value |
Percentage of contribution |
|
A |
1 |
0.77533 |
0.775334 |
14.64 |
0.019 |
44.92 |
|
B |
1 |
0.72659 |
0.726591 |
13.72 |
0.021 |
42.09 |
|
C |
1 |
0.01168 |
0.011680 |
0.22 |
0.663 |
0.68 |
|
D |
1 |
0.00061 |
0.000613 |
0.01 |
0.920 |
0.03 |
|
Error |
4 |
0.21188 |
0.052970 |
|
|
12.27 |
|
Total |
8 |
1.72610 |
|
|
|
|
3.2 Statistical interpretation using the Taguchi approach
In the present study, better criteria were applied for all the output properties of AMF to obtain an S/N ratio more significant. As per the considered criteria, the S/N signal-to-noise ratio should possess a higher value to obtain optimum test conditions. The ranking for the input process factors is acquired using its S/N signal-to-noise ratios with four levels for % porosity and compressive, tensile, and flexural strength, as reported in Table 9. The ranks for the input process factors are obtained to establish the relative magnitude of effects based on the delta statistics [37].
Table 9. Responses acquired in S/N ratios
|
% porosity |
Compressive strength (MPa) |
||||||||
|
Level |
A |
B |
C |
D |
Level |
A |
B |
C |
D |
|
1 |
37.00 |
36.88 |
36.84 |
36.89 |
1 |
18.55 |
19.71 |
20.21 |
19.89 |
|
2 |
36.99 |
36.87 |
36.85 |
36.84 |
2 |
20.26 |
19.89 |
20.17 |
19.97 |
|
3 |
36.56 |
36.82 |
36.87 |
36.83 |
3 |
21.43 |
20.65 |
19.86 |
20.38 |
|
Delta |
0.44 |
0.06 |
0.03 |
0.06 |
Delta |
2.89 |
0.94 |
0.35 |
0.49 |
|
Rank |
1 |
3 |
4 |
2 |
Rank |
1 |
2 |
4 |
3 |
|
Tensile strength (MPa) |
Flexural strength (MPa) |
||||||||
|
Level |
A |
B |
C |
D |
Level |
A |
B |
C |
D |
|
1 |
11.61 |
12.34 |
12.52 |
13.15 |
1 |
12.28 |
12.59 |
13.27 |
13.03 |
|
2 |
12.40 |
12.69 |
12.91 |
12.68 |
2 |
13.44 |
12.90 |
13.11 |
13.37 |
|
3 |
14.55 |
13.53 |
13.13 |
12.73 |
3 |
13.70 |
13.92 |
13.04 |
13.02 |
|
Delta |
2.93 |
1.19 |
0.61 |
0.47 |
Delta |
1.42 |
1.33 |
0.23 |
0.35 |
|
Rank |
1 |
2 |
3 |
4 |
Rank |
1 |
2 |
4 |
3 |
3.3 Confirmation tests
In the DOE approach, the final step is the confirmation of experiments. After investigating the optimal test conditions, the confirmation was performed considering the optimum level of factors. The acquired results were eventually compared with the predicted results [42]. Table 10 demonstrates the comparative results obtained using optimal parameters. It has been observed that there was reasonable agreement between the experimental and predicted results. However, an error of 3.20% for % porosity, 5.99% compressive strength, 9.23% tensile strength, and 3.35% flexural strength (S/N ratios) was observed.
Table 10. Confirmation tests
|
|
Initial parameter combination |
Prediction |
Experimentation |
Improvement in S/N ratio |
|
Level |
A1B1C1D1 |
A1B1C3D1 |
|
|
|
% porosity |
67.45 |
67.74 |
69.91 |
|
|
SN ratio (dB) |
36.57 |
36.72 |
37.89 |
3.20 |
|
|
|
|
|
|
|
Level |
A3B3C2D1 |
A3B3C2D3 |
|
|
|
Compressive strength (MPa) |
8.20 |
8.29 |
7.89 |
|
|
SN ratio (dB) |
18.22 |
18.43 |
17.54 |
5.99 |
|
|
|
|
|
|
|
Level |
A3B3C2D1 |
A3B3C1D1 |
|
|
|
Tensile strength (MPa) |
3.74 |
3.68 |
4.02 |
|
|
SN ratio (dB) |
11.44 |
11.25 |
12.28 |
9.23 |
|
|
|
|
|
|
|
Level |
A3B3C2D1 |
A3B3C1D2 |
|
|
|
Flexural strength (MPa) |
3.80 |
3.81 |
3.94 |
|
|
SN ratio (dB) |
11.59 |
11.62 |
12.01 |
3.35 |
The mechanical properties of the developed AMF with various influential parameters such as powder size, sintering speed, sintering temperature, and foaming agent content have been studied. Furthermore, Taguchi's design of the experiment and ANOVA were performed to have a good correlation between the listed input and output parameters. Based on experimental and DOE approaches, the conclusions below have been drawn.
- These experimental test results show that the powder metallurgy approach helps produce lightweight Aluminium metal foam (AMF) with a uniform homogeneous structure using wax powder as a foaming agent.
- The maximum Porosity 71.30%, Compresssion strength 12.01MPa, Tensile strength 6.16 MPa, Flexural strength 5.18 MPa. The microstructure study reveals that there is no any adequet compostion in the specimen.
- Taguchi's approach reveals that powder size is the most influential parameter, followed by stirring speed, wt. % of foaming agent and sintering temperature affecting the output mechanical properties. Among all, sintering temperature effects as less individually, but as in the case of a combined interaction effect, it affects significantly.
- Research works concludes that the powder metallurgy is the best techniques to develop metal foam with foaming agent as paraffin wax powder it gives the solution to most challenging task to produce metal foam with uniform integraty on entire surfaces with good mechanical properties.
Declaration of Conflicting Interests
The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.
Funding
The author(s) received no financial support for the research, authorship, and/or publication of this article.
ORCID Id
Mahadev Madgule 0000-0001-6584-3787
Sreenivasa C G: 0000-0002-2936-3900
Avinash V Borgaonkar: 0000-0002-7507-7139
Authors Contribution
Mr. Mahadev Madgule: Experimental work about producing metal foam through powder metallurgy technique and literature study about the topic.
Dr. Sreenivasa C. G. : Drafting the journal paper as per the format and check the grammatical mistakes.
Dr. Avinash V Borgaonkar: Implementing the Design of experiments with Taguchi approach.
- Rajak, D. K., Kumaraswamidhas, L. A., & Das, S. 2017. Technical overview of Aluminium alloy foam. Reviews on advanced materials science, 49(1), 68-86.
- A.V. Borgaonkar, V.G. Salunkhe, M. B. Kumbhar, A. R. Koli. S. B. Potdar. Theoretical and Experimental Investigation of Effect of Boundary Conditions on SEA Parameters for Idealized Subsystems, Materials Today: Proceedings.2021; 38(5): 2222-2226.
- Singh, S., & Bhatnagar, N. (2018). A survey of fabrication and application of metallic foams (1925–2017). Journal of Porous Materials, 25(2), 537-554.
- Borgaonkar A.V., Mandale M.B., Potdar S.B. Effect of Changes in Fiber Orientations on Modal Density of Fiberglass Composite Plates, Materials Today: Proceedings. 2018; 5: 5356-5364.
- Borgaonkar A. V. Potdar S. B., Frictional and Wear Behavior of Epoxy Resin Based Nano-composite in Dry Sliding Contact. In: Jena H., Katiyar J. K. and Pattnaik A. (eds) Tribology of Polymer and Polymer Composite for Industry 4.0, Springer Singapore, 2021. pp. 1-13.
- Kulshreshtha, A., & Dhakad, S. K. (2020). Preparation of metal foam by different methods: A review. Materials Today: Proceedings, 26, 1784-1790.
- Borgaonkar, A.V., Mandale M.B., Salunkhe, V.G. Potdar S.B. Experimental investigations of different fiber orientations on damping loss factor of fiberglass composite specimens. Materials Today: Proceedings, 2020; 26: 256-260.
- Patel, P., Bhingole, P. P., & Makwana, D. (2018). Manufacturing, characterization and applications of lightweight metallic foams for structural applications. Materials Today: Proceedings, 5(9), 20391-20402.
- Bauer, B., Kralj, S., & Bušić, M. (2013). Production and application of metal foams in casting technology. Tehnicki Vjesnik/Technical Gazette, 20(6).
- Babcsan, N., Beke, S., Makk, P., Szamel, G., & Kadar, C. (2014). Pilot production and properties of ALUHAB aluminium foams. Procedia Materials Science, 4, 127-132.
- Bafti, H., & Habibolahzadeh, A. (2013). Compressive properties of Aluminium foam produced by powder-Carbamide spacer route. Materials & Design (1980-2015), 52, 404-411.
- Gîngu, O., Sima, G., Teișanu, C., & Bucşe, I. G. (2018). New Injection Moulding Techniques for Automotive Aluminium-Based Foams-Part I. In Applied Mechanics and Materials (Vol. 880, pp. 248-255). Trans Tech Publications Ltd.
- Li, Z., Xi, C., Jing, L., Wang, Z., & Zhao, L. (2014). Effect of loading rate on the compressive properties of open-cell metal foams. Materials Science and Engineering: A, 592, 221-229.
- Güner, A., Arıkan, M. M., & Nebioglu, M. (2015). New approaches to Aluminium integral foam production with casting methods. Metals, 5(3), 1553-1565.
- Shimizu, T., & Matsuzaki, K. (2003). New method to produce foam metals using water base binder. Journal of the Japan Society of Powder and Powder Metallurgy, 50(3), 177-181.
- Rajak, D. K., & Gupta, M. (2020). Manufacturing Methods of Metal Foams. In An Insight Into Metal Based Foams (pp. 39-52). Springer, Singapore.
- García-Moreno, F. (2016). Commercial applications of metal foams: Their properties and production. Materials, 9(2), 85.
- Borgaonkar A., Mandale M.B., Chaitanya C.S., Potdar S.B. Statistical Energy Analysis Parameters Investigation of Composite Specimens Employing Theoretical and Experimental Approach. In: Sahoo S. (eds) Recent Advances in Layered Materials and Structures. Materials Horizons: From Nature to Nanomaterials. Springer, Singapore. 2021. pp.307-330.
- Bouwhuis, B. A., McCrea, J. L., Palumbo, G., & Hibbard, G. D. (2009). Mechanical properties of hybrid nanocrystalline metal foams. Acta Materialia, 57(14), 4046-4053.
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- Dukhan, N., Rayess, N., & Hadley, J. (2010). Characterization of Aluminium foam–polypropylene interpenetrating phase composites: flexural test results. Mechanics of Materials, 42(2), 134-141.
- D’Urso, G., & Maccarini, G. (2012). The formability of Aluminium foam sandwich panels. International journal of material forming, 5(3), 243-257.
- Kim, A., Hasan, M. A., Nahm, S. H., & Cho, S. S. (2005). Evaluation of compressive mechanical properties of Al-foams using electrical conductivity. Composite Structures, 71(2), 191-198.
- Kadkhodapour, J., & Raeisi, S. (2014). Micro–macro investigation of deformation and failure in closed-cell Aluminium foams. Computational Materials Science, 83, 137-148.
- Jung, A., & Diebels, S. (2019). Micromechanical characterization of metal foams. Advanced Engineering Materials, 21(8), 1900237.
- Jung, A., & Diebels, S. (2014). Hybrid metal foams: experimental observations and phenomenological modelling. Technische Mechanik-European Journal of Engineering Mechanics, 34(1), 12-22.
- Jung, A., Wocker, M., Chen, Z., & Seibert, H. (2015). Micro tensile testing of open-cell metal foams—Experimental setup, micromechanical properties. Materials & Design, 88, 1021-1030.
- Duarte, I., & Ferreira, J. M. (2016). Composite and nanocomposite metal foams. Materials, 9(2), 79.
- García-Moreno, F. (2016). Commercial applications of metal foams: Their properties and production. Materials, 9(2), 85.
- Orbulov, I. N., & Szlancsik, A. (2018). On the mechanical properties of Aluminium matrix syntactic foams. Advanced Engineering Materials, 20(5), 1700980.
- Shunmugasamy, V. C., & Mansoor, B. (2018). Compressive behavior of a rolled open-cell Aluminium foam. Materials Science and Engineering: A, 715, 281-294.
- Nawaz, A., & Rani, S. (2021). Fabrication and evaluation of percent porosity and density reduction of aluminium alloy foam. Materials Today: Proceedings, 47, 6025-6029.
- Liu, P. S. (2010). A new method for calculating the specific surface area of porous metal foams. Philosophical magazine letters, 90(6), 447-453.
- Wang, X. Z., Wu, L. Z., & Wang, S. X. (2009). Tensile and shear properties of aluminium foam. Materials Technology, 24(3), 161-165.
- Uzun, A., Karakoc, H., Gokmen, U., Cinici, H., & Turker, M. (2016). Investigation of mechanical properties of tubular Aluminium foams. International Journal of Materials Research, 107(11), 996-1004.
- Shi, T., Chen, X., Cheng, Y., Liu, Y., Zhang, H., & Li, Y. (2018). Microstructure and compressive properties of Aluminium foams made by 6063 Aluminium alloy and pure Aluminium. Materials transactions, M2017300.
- Naeem, M. A., Gábora, A., & Mankovits, T. (2020). Influence of the manufacturing parameters on the compressive properties of closed cell Aluminium foams. Periodica Polytechnica Mechanical Engineering, 64(2), 172-178.
- Mahadev, M., Sreenivasa, C. G., & Shivakumar Mr, K. M. (2018, June). A Review on Prodution of Aluminium Metal Foams. In Materials Science and Engineering Conference Series 376(1), 1-12.
- Ali, H., Gábora, A., Naeem, M. A., Kalácska, G., & Mankovits, T. (2021). Effect of the manufacturing parameters on the pore size and Porosity of closed-cell hybrid Aluminium foams. International Review of Applied Sciences and Engineering, 12(3), 230-237.
- Solórzano, E., Reglero, J. A., Rodríguez-Pérez, M. Á., de Saja, J. A., & Rodríguez-Méndez, M. L. (2007). Improvement of the foaming process for 4045 and 6061 aluminium foams by using the Taguchi methodology. Journal of materials science, 42(17), 7227-7238.
- Surace, R., Bruno, S., De Filippis, L. A. C., & Ludovico, A. D. (2009). Multi-objective optimization of aluminium foam manufacturing parameters. International journal of simulation modelling, 8(2), 81-89.
- Borgaonkar A, Syed I. Tribological Behavior Prediction of Composite MoS2-TiO2 Coating Using Taguchi Coupled Artificial Neural Network Approach, Proc. IMechE, Part C: Journal of Mechanical Engineering Science, 2021: 0(0): 1-16.
- Uzun, A., 2019. Production of aluminium foams reinforced with silicon carbide and carbon nanotubes prepared by powder metallurgy method. Composites Part B: Engineering, 172, pp.206-217.
- Ding, X., Liu, Y., Chen, X., Zhang, H. and Li, Y., 2018. Optimization of cellular structure of aluminum foams produced by powder metallurgy method. Materials Letters, 216, pp.38-41.
- Geramipour, T. and Oveisi, H., 2017. Effects of foaming parameters on microstructure and compressive properties of aluminum foams produced by powder metallurgy method. Transactions of Nonferrous Metals Society of China, 27(7), pp.1569-1579.
No competing interests reported.