Fabrication and Compressive Properties of Low to Medium Porosity Closed-Cell Porous Aluminum Using PMMA Space Holder Technique

Abstract

In recent years, closed-cell porous Aluminum (Al) has drawn increasing attention, particularly in the applications requiring reduced weight and energy absorption capability such as in the automotive and aerospace industries. In the present work, porous Al with closed-cell structure was successfully fabricated by powder metallurgy technique using PMMA as a space holder. The effects of the amount of PMMA powder on the porosity, density, microstructure and compressive behaviors of the porous specimens were systematically evaluated. The results showed that closed-cell porous Al having different porosities (12%–32%) and densities (1.6478 g/cm3, 1.5125 g/cm3 and 1.305 g/cm3) could be produced by varying the amount of PMMA (20–30 wt %). Meanwhile, the compressive behavior results demonstrated that the plateau stress decreased and the energy absorption capacity increased with increasing amount of PMMA. However, the maximum energy absorption capacity was achieved in the closed-cell porous Al with the addition of 25 wt % PMMA. Therefore, fabrication of closed-cell porous Al using 25 wt % PMMA is considered as the optimal condition in the present study since the resultant closed-cell porous Al possessed good combinations of porosity, density and plateau stress, as well as energy absorption capacity.

Mechanical properties of melt infiltration and powder metallurgy fabricated aluminum metal matrix composite

“…The higher the volume fraction of the space holder, the thinner the closed-cell walls and the lower the density of the foam. Similar observations are reported in the works of Manonukul et al 43 and Jamal et al 41 It is therefore evident that the density post sintering and porosity of the aluminum matrix can be tailored by varying the content of graphene and space holder material. EDS analysis for sample 5 is conducted and shown in Figure 10.…”

“…These screening results were also supported by data from literature. 40,41 Sample preparation procedure Powder metallurgy. The PM samples were prepared based on the main steps and process parameters outlined in Table 2.…”

Microstructure and Mechanical Properties of Metal Foams Fabricated via Melt Foaming and Powder Metallurgy Technique: A Review

“…Al and Mg foams were developed through the powder metallurgy technique, using (PMMA) particles as space holders, resulting in efficient control over porosities and densities by varying the PMMA particle content. PMMA particles leave almost negligible residue on decomposition during sintering [ 152 , 153 , 154 ]. This technique has been employed to fabricate various metal foams, as mentioned in Table 6 .…”

Application of Aluminium Flakes in Fabrication of Open-Cell Aluminium Foams by Space Holder Method

“…The use of metal foams depends on their basic characteristics such as relative density, cell structure, wall thickness, strut integrity, and cell morphology homogeneity [12,13,14]. The most common type of metallic foam is the aluminum foam, which is widely preferred due to its important mechanical and natural properties.…”

“…Metal foams find many applications in areas such as the naval industry, aerospace, mechanical or chemical engineering and can be used as heat exchangers, energy or sound absorbers, filters, and implants in medicine. The use of metal foams depends on their basic characteristics such as relative density, cell structure, wall thickness, strut integrity, and cell morphology homogeneity [ 12 , 13 , 14 ]. The most common type of metallic foam is the aluminum foam, which is widely preferred due to its important mechanical and natural properties.…”