OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 25 No. 4 2023 A synergistic approach to the development of lightweight aluminium-based porous metallic foam using stir casting method Shyam Sharma a, Rahul Khatri b, Anurag Joshi c, * Department of Mechanical Engineering, Manipal University Jaipur, Rajasthan, 303007, India a https://orcid.org/0000-0002-1510-5871, shyamsunder.sharma@jaipur.manipal.edu; b https://orcid.org/0000-0003-1589-533X, rahul.khatri@jaipur.manipal.edu; с https://orcid.org/0000-0002-8231-9423, anuragjoshi355@gmail.com 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. 255–267 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.4-255-267 ART I CLE I NFO Article history: Received: 04 September 2023 Revised: 27 September 2023 Accepted: 12 November 2023 Available online: 15 December 2023 Keywords: Metallic foam Stir casting Porous foam Light weight material ABSTRACT Introduction. A synergetic approach to the development of lightweight aluminium metal foam by stir casting process is presented and various mechanical properties and microstructure are tested. The purpose of this study is due to the constant industrial demand for lightweight materials and increased research interest in porous substrates, mainly due to its unique properties. Materials and method.. The method used for developing metallic aluminium foam was stir casting with calcium carbonate as a foaming agent to achieve a target interconnected porous microenvironment on a metal foam substrate. Results and Discussion. A set of physical properties, such as apparent density (1.8 g/cm3), relative density (0.67 g/cm3) and porosity (30 %) of the developed aluminium-based metal foams, is stated as the result. The developed metal foam has a strength-to-weight ratio 67 % higher than that of the base material. In addition, the results of field emission scanning electron microscopy of the developed metal foam confirm the presence of a porous network with a pore size from 0.075 mm to 1.43 mm. Energy dispersive spectroscopy confirmed the presence of the desired elements with minimal contamination in the developed aluminium foam substrates. Metal foam demonstrates a higher compressive strength (607 kN) compared to the base metal (497 kN). The mechanical characteristics of the developed metal foam substrate (hardness, compressive strength and impact energy) show the expected results compared to the base material. In general, the developed aluminium foam substrate established a promising route to the development of highly performance lightweight metal foam for shock absorber and acoustic applications. For citation: Sharma S.S., Khatri R., Joshi A. A synergistic approach to the development of lightweight aluminium-based porous metallic foam using stir casting method. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 4, pp. 255–267. DOI: 10.17212/1994-6309-2023-25.4-255-267. (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 Natural materials with a cellular structure, such as wood, bone, pumice stone and leaf structure, have historically found use due to its unique properties. Polymer foamed material, which is also called “manmade foam”, has a wide application and gives the object a unique structure. It is also used as a protective casing in various equipment, such as bicycle helmets, refrigerator enclosures, etc. [1]. The unique properties of natural cellular materials prompted researchers to develop a metal foam. The first metal foamed material was reported by De Moeller in 1925, but many authors referred to a patent dated from 1960 to 1970 [2]. The 2-D honeycomb structure has many of the metal foam’s mechanical properties. Compared to metal foam, honeycomb structures have a simple structure, although very similar; the cost of manufacturing metallic foam is high and, and its manufacturing technology is quite complicated. Among the methods of obtaining metal foam, casting and powder metallurgy are the most common. A large amount of metal foam is made from various materials such as steel, aluminium and titanium. Methods of electrodeposition, chemical vapor
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