OBRABOTKAMETALLOV Vol. 25 No. 4 2023 technology A systematic review of processing techniques for cellular metallic foam production Shyam Sharma 1, a, Anurag Joshi 1, b, *, Yogendra Rajpoot 2, c 1 Department of Mechanical Engineering, Manipal University Jaipur, Rajasthan, 303007, India 2 Department of Mechanical Engineering, Rajkiya Engineering College Mainpuri, Uttar Pradesh, 205119, India a https://orcid.org/0000-0002-1510-5871, shyamsunder.sharma@jaipur.manipal.edu; b https://orcid.org/0000-0002-8231-9423, anuragjoshi355@gmail.com; с https://orcid.org/0000-0002-9662-0903, yogendrasingh.rajpoot@recmainpuri.in Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2023 vol. 25 no. 4 pp. 22–35 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.4-22-35 ART I CLE I NFO Article history: Received: 06 August 2023 Revised: 11 August 2023 Accepted: 23 August 2023 Available online: 15 December 2023 Keywords: Melt route method Powder metallurgy Deposition technique Foaming agent ABSTRACT Introduction. The paper presents a comprehensive overview of the manufacturing methods, materials, properties, and challenges associated with cellular metallic foams, primarily focusing on aluminum and titaniumbased foams. Cellular metallic foams are gaining interest due to its unique combination of low density, high stiffness, and enhanced energy absorption capabilities. Cellular metallic foam is renowned for its special combinations of physical and mechanical characteristics, containing their increased stiffness, specific strength at high temperatures, light weight, and good energy absorption at relatively low plateau stress. It has extensive uses in the automotive, shipbuilding and space industries. It has high porosity, low relative density and high strength, which increases performance of the product. The aerospace and automotive industries require a material with a high strength-toweight ratio. Methods. To meet this need, many metal foam production methods have been developed, such as melt route method, deposition method and powder metallurgy method. Melt route method is widely used to manufacture metallic foam as compared to other methods. Results and Discussion. In the production of aluminum foams, the melt route method is usually used. Titanium hydride (TiH2) has been a popular foaming agent, but its high decomposition rate and cost limitations have led to the development of alternative foaming agents, such as CaCO3 (calcium carbonate). Titanium foam is often manufactured using the space holder method. This method involves mixing titanium powder with a space holder material, forming a preform, and then sintering to remove the space holder and produce a porous structure as the space holder method allows for precise control over the properties of the foam, including pore size, porosity, and relative density. Results also indicate that porosity in cellular metallic foams can range from 50 % to 95 %, as reported in various journals. Pore structures can include mixed types, open cells, and closed cells, each offering different mechanical and thermal properties. It is also observed from various literature sources that relative density, which is the ratio of the foam’s density to the bulk material’s density, varies from 0.02 to 0.44 based on the production method used. For citation: Sharma S.S., Joshi A., Rajpoot Y.S. A systematic review of processing techniques for cellular metallic foam production. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 4, pp. 22–35. DOI:10.17212/1994-6309-2023-25.4-22-35. (In Russian). ______ * Corresponding author Joshi Anurag, Ph.D. (Engineering), Assistant Professor Manipal University Jaipur, 303007, Rajasthan, India Tel.: +91-9772844555, e-mail: anuragjoshi355@gmail.com Introduction In many research papers, cellular materials are called new ones. Initially it was reported by De Meller in 1925. His patent proposed foaming of light metals by injection of an inert gas or using a blowing agent, gas-eutectic reaction, etc. These processes require high capital investment and safety equipment because gas release during the foaming processes [1]. Metallic foam can be defined as light weighted material with high stiffness. When blowing agent is added in liquid metal and gases are released, which are trapped after solidification, we get metallic foam, for example, aluminum one. The interest of researchers in developing metallic foams lies in obtaining unique properties such as low specific weight, high gas permeability, high stiffness, low thermal conductivity, electrical insulation properties and high shock-absorbing capacity.
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