Microstructure and Mechanical Behavior of CaCO3-Doped Al–Al2O3 Composite Foams Produced by Powder Metallurgy

Abstract

In this study, closed-cell composite metal foam production was performed using the powder metallurgy method. Therefore, 7, 12, and 17 wt.% CaCO3 as a foaming agent was added to the Al–Al2O3 powder mixture containing 5 wt.% Al2O3 after the grinding process. The CaCO3-added Al–Al2O3 powder mixture was mixed wet and pulverized in a mortar after drying in an oven. Three separate powder mixtures were formed under a pressure of 40 MPa and sintered at 550 °C for 1 h and then at 1000 °C for 4 h. The samples' densities, mineralogical properties, microstructures, adsorption isotherms, and compressive strengths were investigated after sintering. The effects of different CaCO3 ratios on the mechanical and microstructural properties of the composite metal foam were investigated under specific production conditions. The foam material produced from the mixture with 7 wt.% CaCO3 added by weight had the highest compressive strength and a more homogeneous pore distribution.

Keywords

• Ceramic
• metal
• composite
• foam
• powder metallurgy

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