An experimental research on production practicability of open cell aluminum metal foams and applicability for 3d modelling

Energy efficiency gaining more importance because of depleting energy resources at the present day. One of the most efficient methods to overcome that problem is lightening the materials. Foam metals have high volumes but very low relative densities. These are interesting subjects because their use in various fields for different purposes such as filtration, heat exchanger or energy, sound, radiation and vibration damping etc. In this study, production methods of open cell foam metals classified and explained, the history of foam metals referred, and a 3D foam metal was designed and analyzed as suitable for production processes. In accordance with this 3D design, liquid state process selected which includes investment casting with polymer foams and casting methods with space-holding fillers. Replication of a polyurethane reticulated sponge was performed by the investment casting method with polymer foams. Secondly, polymer foam space-holder used to aim to produce open-cell foam metal by casting aluminum into cavities. In the third method, spherical spacers were used. The spheres were filled into a mold. It was desired to obtain open cell foam metal from the geometry of the area remaining from the spheres by casting aluminum into this mold. Fiber holders were used as the fourth method. The most suitable production process was seen casting around spherical space-holders.