OBRABOTKAMETALLOV Vol. 25 No. 4 2023 266 MATERIAL SCIENCE 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 fi eld emission scanning electron microscopy of the developed metal foam confi rm the presence of a porous network with a pore size from 0.075 mm to 1.43 mm. Energy dispersive spectroscopy confi rmed 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 References 1. Broxtermann S., Su M.M., Hao H., Fiedler T. Comparative study of stir casting and infi ltration casting of expanded glass-aluminium syntactic foams. Journal of Alloys and Compounds, 2020, vol. 845, p. 155415. DOI: 10.1016/j.jallcom.2020.155415. 2. Banhart J. Light-metal foams history of innovation and technological challenges. Advanced Engineering Materials, 2013, vol. 15 (3), pp. 82–111. DOI: 10.1002/adem.201200217. 3. Banhart J., Seeliger H.-W. Aluminium foam sandwich panels: manufacture, metallurgy and applications. Advanced Engineering Materials, 2008, vol. 10 (9), pp. 793–802. DOI: 10.1002/adem.200800091. 4. Karuppasamy R., Barik D., Sivaram N.M., Dennison M.S. Investigation on the eff ect of aluminium foam made of A413 aluminium alloy through stir casting and infi ltration techniques. International Journal of Materials Engineering Innovation, 2020, vol. 11 (1), pp. 34–50. DOI: 10.1504/IJMATEI.2020.104790. 5. Sharma S.S., Rajpoot Y.S. Development of aluminum metal foam using blowing agent. IOP Conference Series: Materials Science and Engineering, 2018, vol. 377 (1), p. 012150. DOI: 10.1088/1757-899X/377/1/012150.
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