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Manufacturing challenges in obtaining tailor-made closed-cell structures in metallic foams

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The evolution of closed-cell aluminum foam synthesized by titanium hydride decomposition is explained on the basis of foam stability and gravity-induced drainage of liquid. While the average pore size progressively increases due to TiH2 decomposition, the aspect ratio shows a sudden transition during the holding period. The sudden increase in aspect ratio with the major axis transverse to the growth direction is explained on the basis of the loss of elasticity of the cell wall due to drainage and subsequent cell wall collapse due to the weight of the overlying foam. Intermetallic particles with a high aspect ratio distributed in the cell wall matrix significantly improve the stability of the liquid foam. It is demonstrated that by varying a single process parameter, such as the holding time, foams with a wide range of structural parameters are accessed. The Gibson and Ashby model showed good correlation with the plateau stress and Young’s modulus results presented in this work.

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Correspondence to B. S. S. Daniel.

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This article was originally presented at the First International & 22nd All India Manufacturing Technology Design & Research Conference (22nd AIMTDR), 21st-23rd December 2006, IIT Roorkee, India.

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Raj, R.E., Daniel, B.S.S. Manufacturing challenges in obtaining tailor-made closed-cell structures in metallic foams. Int J Adv Manuf Technol 38, 605–612 (2008).

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