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Hierarchical Porous Cu with Trimodal Porosity Produced Through Investment Casting and Dealloying

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Abstract

An open cellular lattice structure based on a cubic body diagonal (CBD) topology is fabricated by vacuum-assisted investment casting of Al-33 wt.% Cu eutectic alloy using 3D printed polymer preform with a pore size of a few millimeters. The CBD struts showed lower microhardness (\(\approx \)150 HV) compared to the bulk master alloy (\(\approx \)191 HV) due to the coarser eutectic resulting from very slow cooling rate (0.04\(^{\circ }\)C/s) inside the ceramic mold in the vacuum chamber. The metallic lattice is subsequently dealloyed in NaOH producing a hierarchically porous Cu structure with additional porosity at micro and nanoscales. Optimum dealloyed conditions are found to be 1 M NaOH at 60\(^{\circ }\)C to obtain uniform nanoporous Cu within the Al\(_2\)Cu eutectic lamellae. The morphology of the nanoporous copper ligaments is affected by solution temperature but is less sensitive to its concentration. The depth of dealloying within CBD struts follows a power law scaling with the dealloying duration with an exponent of 0.5. The macroporous, as well as the partially dealloyed hierarchical porous structures exhibit quasi-brittle failure under compression loading with a peak stress of 4 MPa and 1.5 MPa, respectively.

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Acknowledgement

KRM and AM acknowledge funding from the SERB, Department of Science and Technology, India under Grant CRG/2018/004005.

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Authors and Affiliations

  1. School of Minerals, Metallurgical and Materials Engineering, Indian Institute of Technology Bhubaneswar, Arugul, Jatni, Khurda, Odisha, 752050, India

    Deepak Panda, Ramreddy Yara, Sudhansu Sekhar Nath, Animesh Mandal & Kodanda Ram Mangipudi

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  1. Deepak Panda
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  2. Ramreddy Yara
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  3. Sudhansu Sekhar Nath
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  4. Animesh Mandal
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  5. Kodanda Ram Mangipudi
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Correspondence to Kodanda Ram Mangipudi.

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Panda, D., Yara, R., Nath, S.S. et al. Hierarchical Porous Cu with Trimodal Porosity Produced Through Investment Casting and Dealloying. JOM 76, 1680–1689 (2024). https://doi.org/10.1007/s11837-024-06375-y

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