Manufacturing of Open-Cell Zn-22Al-2Cu Alloy Foams by a Centrifugal-Replication Process

Centrifugal force was used to produce open-cell Zn-22Al-2Cu alloy foams by the replication method. Three different sizes (0.50, 0.69, and 0.95 mm) of NaCl spherical particles were used as space holders. A relatively low infiltration pressure was required to infiltrate completely the liquid metal into the three pore sizes, and it was determined based on the centrifugation system parameters. The infiltration pressure required was decreased when the diameter of the particle was increased. The porosity of the foam was increased from 58 to 63 pct, when the pore size was increased from 0.50 to 0.95 mm, while the relative density was decreased from 0.42 to 0.36. The NaCl preform was preheated to avoid the freezing and to keep the rheological properties of the melt. The centrifugal-replication method is a suitable technique for the fabrication of open-cell Zn-Al-Cu alloy foams with small pore size. The compressive mechanical properties of the open-cell Zn-22Al-2Cu foams increased when the pore size decreased.