Synthesis and characterization of copper foams through a powder metallurgy route using a compressible and lubricant space-holder material

Abstract

In the present work, a compressible and lubricating space-holder material commonly known as “acrawax” was used to process Cu foams with various pore sizes and various porosities. The foams were processed without using binders to avoid contamination of their metal matrices. The lubricant space-holder material was found to facilitate more uniform flow and distribution of metal powder around the surface of the space holder. In addition, the use of acrawax as a space-holder material yielded considerably dense cell walls, which are an essential prerequisite for better material properties. The foams processed with a smaller-sized space holder were found to exhibit better electrical and mechanical properties than those processed with a coarser-sized space holder. The isotropic pore shape, uniform pore distribution throughout the metal matrix, and uniform cell wall thickness were found to enhance the properties pertaining to fine-pore foam samples. The processed foams exhibit properties similar to those of the foams processed through the lost-carbonate sintering process.

Keywords

copper foam / powder metallurgy / space holder / acrawax / flexural strength / sintering / electrical resistivity

References

[1] Dukhan N. Metal Foams: Fundamentals and Applications, DEStech Publications, 2012, USA, Pennsylvania 381.

[2] Goodall R. Porous Metals: Foams and Sponges, [in] Advances in Powder Metallurgy: Properties, Properties and Applications, 2013, Oxford, Woodhead publishing limited 273.

[3] Stergioudi F., Kaprara E., Simeonidis K., Sagris D., Mitrakas M., Vourlias G., Michailidis N. Copper foams in water treatment technology: removal of hexavalent chromium. Mater. Des., 2015, 87, 287.

[4] Jo H., Cho Y., Choi M., Cho J., Um J.H., Sung Y., Choe H. Novel method of powder-based processing of copper nanofoams for their potential use in energy applications. Mater. Chem. Phys., 2014, 145(1–2): 6.

[5] Etiemble A., Adrien J., Maire E., Idrissi H., Reyter D., Roué L. 3D morphological analysis of copper foams as current collectors for Li-ion batteries by means of X-ray tomography. Mater. Sci. Eng. B, 2014, 187, 1.

[6] Lu W., Zhao C.Y., Tassou S.A. Thermal analysis on metal-foam filled heat exchangers. Part I: Metal-foam filled pipes. Int. J. Heat Mass Trans., 2006, 49(15–16): 2751.

[7] Baloyo J.M. Open-cell porous metals for thermal management applications: fluid flow and heat transfer. J. Mater. Sci. Technol., 2017, 33(3): 265.

[8] Moon C., Kim D., Abadi G.B., Yoon S.Y., Kim K.C. Effect of ligament hollowness on heat transfer characteristics of open-cell metal foam. Int. J. Heat Mass Trans., 2016, 102, 911.

[9] Liu X.H., Huang H.Y., Xie J.X. Effect of strain rate on the compressive deformation behaviors of lotus-type porous copper. Int. J. Miner. Metall. Mater., 2014, 21(7): 687.

[10] Ashby M.F., Evans T., Fleck N.A., Gibson L.J., Hutchinson J.W., Wadley H.N.G. Metal Foams: A Design Guide, 2000 6.

[11] Banhart J. Manufacture, characterisation and application of cellular metals and metal foams. Prog. Mater. Sci., 2001, 46(6): 559.

[12] Dunand D.C. Processing of titanium foams. Adv. Eng. Mater., 2004, 6(6): 369.

[13] Garcia-Avila M., Rabiei A. Effect of sphere properties on microstructure and mechanical performance of cast composite metal foams. Metals, 2015, 5(2): 822.

[14] Garcia-Avila M., Portanova M., Rabiei A. Ballistic performance of composite metal foams. Compos. Struct., 2015, 125, 202.

[15] Parvanian A.M., Saadatfar M., Panjepour M., Kingston A., Shepperd A.P. The effects of manufacturing parameters on geometrical and mechanical properties of copper foams produced by space holder technique. Mater. Des., 2014, 53, 681.

[16] Parvanian A.M., Panjepour M. Mechanical behavior improvement of open-pore copper foams synthesized through space holder technique. Mater. Des., 2013, 49, 834.

[17] Ye B., Dunand D.C. Titanium foams produced by solid-state replication of NaCl powders. Mater. Sci. Eng. A, 2010, 528(2): 691.

[18] Jha N., Mondal D.P., Majumdar J.D., Badkul A., Jha A.K., Khare A.K. Highly porous open cell Ti-foam using NaCl as temporary space holder through powder metallurgy route. Mater. Des., 2013, 47, 810.

[19] Jakubowicz J., Adamek G., Devidar M. Titanium foam made with saccharose as a space holder. J. Porous Mater., 2013, 20(5): 1137.

[20] Michailidis N., Stergioudi F., Tsouknidas A., Pavlidou E. Compressive response of Al-foams produced via a powder sintering process based on a leachable space-holder material. Mater. Sci. Eng. A, 2011, 528(3): 1662.

[21] Bekoz N., Oktay E. Effects of carbamide shape and content on processing and properties of steel foams. J. Mater. Process. Technol., 2012, 212(10): 2109.

[22] Tian D.R., Pang Y.H., Yu L., Sun L. Production and characterization of high porosity porous Fe-Cr-C alloys by the space holder leaching technique. Int. J. Miner. Metall. Mater., 2016, 23(7): 793.

[23] Sharma M., Gupta G.K., Modi O.P., Prasad B.K., Gupta A.K. Titanium foam through powder metallurgy route using acicular urea particle as space holder. Mater. Lett., 2011, 65(21–22): 3199.

[24] Mansourighasri A., Muhamad N., Sulong A.B. Processing titanium foams using tapioca starch as a space holder. J. Mater. Process. Technol., 2012, 212(1): 83.

[25] Ahmed Y.M.Z., Riad M.I., Sayed A.S., Ahlam M.K., Shalabi M.E.H. Correlation between factors controlling preparation of porous copper via sintering technique using experimental design. Powder Technol., 2007, 175(1): 48.

[26] Esen Z., Bor S. Processing of titanium foams using magnesium spacer particles. Scripta Mater., 2007, 56(5): 341.

[27] Mutlu I., Yeniyol S., Oktay E. Production and precipitation hardening of beta-type Ti–35Nb–10Cu alloy foam for implant applications. J. Mater. Eng. Perferm., 2016, 25(4): 1586.

[28] Arifvianto B., Zhou J. Fabrication of metallic biomedical scaffolds with the space holder method: a review. Materials, 2014, 7(5): 3588.

[29] Khodaei M., Meratian M., Savabi O. Effect of spacer type and cold compaction pressure on structural and mechanical properties of porous titanium scaffold. Powder Metall., 2015, 58(2): 152.

[30] Amigó V., Reig L., Busquets D.J., Ortiz J.L., Calero J.A. Analysis of bending strength of porous titanium processed by space holder method. Powder Metall., 2011, 54(1): 67.

[31] Sharma M., Gupta G.K., Modi O.P., Prasad B.K. PM processed titanium foam: influence of morphology and content of space holder on microstructure and mechanical properties. Powder Metall., 2013, 56(1): 55.

[32] Wang B., Zhang E. On the compressive behaviour of sintered porous coppers with low-to-medium porosities-Part II: Preparation and microstructure. Int. J. Mech. Sci., 2008, 50(3): 550.

[33] Xiong J.Y., Li Y.C., Wang X.J., Hodgson P.D., Wen C.E. Titanium-nickel shape memory alloy foams for bone tissue engineering. J. Mech. Behav. Biomed. Mater., 2008, 1(3): 269.

[34] Kanoko Y., Ameyama K., Tanaka S., Hefler B. Production of ultra-thin porous metal paper by fibre space holder method. Powder Metall., 2014, 57(3): 168.

[35] El-Hadek M.A., Kaytbay S. Mechanical and physical characterization of copper foam. Int. J. Mech. Mater. Des., 2008, 4(4): 63.

[36] Zhao Y.Y., Fung T., Zhang L.P., Zhang F.L. Lost carbonate sintering process for manufacturing metal foams. Scripta Mater., 2005, 52(4): 295.

[37] Jia J.G., Siddiq A.R., Kennedy A.R. Porous titanium manufactured by a novel powder tapping method using spherical salt bead space holders: characterisation and mechanical properties. J. Mech. Behav. Biomed. Mater., 2015, 48, 229.

[38] Khodaei M., Meratian M., Savabi O., Razavi M. The effect of pore structure on the mechanical properties of titanium scaffolds. Mater. Lett., 2016, 171, 308.

[39] Mondal D.P., Patel M., Das S., Jha A.K., Jain H., Gupta G., Arya S.B. Titanium foam with coarser cell size and wide range of porosity using different types of evaporative space holders through powder metallurgy route. Mater. Des., 2014, 63, 89.

[40] Mondal D.P., Patel M., Jain H., Jha A.K., Das S., Dasgupta R. The effect of particle shape and strain rate on microstructure and compression deformation response of pure Ti-foam made using acrowax as space holder. Mater. Sci. Eng. A., 2015, 625, 331.

[41] Sharma M., Modi O.P., Kumar P. Experimental modelling of copper foams processed through powder metallurgy route using a compressible space holder material. J. Porous Mater., 2017, 24(6): 1581.

[42] Li B.Q., Lu X. The effect of pore structure on the electrical conductivity of Ti. Transp. Porous Media, 2011, 87(1): 179.