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Journal of Manufacturing Processes
Article in Journal of Manufacturing Processes · September 2015

DOI: 10.1016/j.jmapro.2015.08.006
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JMP-362; No. of Pages 9 ARTICLE IN PRESS
Journal of Manufacturing Processes xxx (2015) xxx–xxx
Contents lists available at ScienceDirect
Journal of Manufacturing Processes

j ou rn a l h o me page :
Role of fine size zircon sand ceramic particle on controlling the cell
morphology of aluminum composite foams
∗
Suresh Kumar, O.P. Pandey
Metallurgical Research Lab, School of Physics and Materials Science, Thapar University, Patiala 147004, Punjab, India
A R T I C L E I N F O A B S T R A C T
Article history:
Composite foams exhibit unique properties such as light weight, blast palliation, sound absorption,
Received 10 December 2014
high energy absorption, and flame resistance. In the present investigation, role of fine size zircon sand
Received in revised form 12 August
ceramic particle on controlling the cell morphology of LM13 alloy composite foams has been studied. For
2015 Accepted 13 August 2015
Available online xxx this pur- pose LM13 piston alloy of near eutectic composition is used as foaming matrix material and
zircon sand ceramic particles as reinforcement. Composite foam was developed by stir casting route at
Keywords:
different temperatures. Variation in microstructures of the composite foam is observed with the addition
Metal composite foam of zircon sand ceramic particles and also with varying foaming temperatures. The results show that the
CaCO3 cell morphology parameters such as cell size, node and ligament length increases with increasing
Cell size foaming temperature. However, the addition of zircon sand ceramic particles leads to decrement in the
Zircon sand ligament length with increasing foaming temperature.
© 2015 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
. Past tense
. Present tense
1. Introduction
controlled by the foaming process where viscosity of the aluminum
melt has be controlled by addition of Ca and continuous stirring of
Metallic foams, as a new class of engineering materials, offer
the melt. The average cell diameter of aluminum foams decreases
a unique combination of properties such as low density, energy
with increasing viscosity of the melt. Many studies have been
absorption capability, high stiffness and strength. These improved
carried out to optimize the microstructural properties of
properties of the metallic foams make them highly desirable
aluminum foams as it influences the above said properties which
materials for different engineering applications [1–4]. Recent
are of at most importance. This includes the cell wall thickness,
improvements in the production methods for metallic foams have
node size, ligament length and interdependent relationship of
offered a variety of applications in different fields such as the auto-
foam density with cell size [4–6]. Since all these microstructural
mobile, railway and aerospace industries [5]. In these applications,
properties are believed to originate from manufacturing condition
the composite foam is subjected to high-velocity deformations.
of metallic foams [3,7], it is of interest to modify the processing
Miyoshi et al. [3] have shown the application of aluminum com-
conditions in order to achieve more uniform cell size distribution
posite foam as a functional material for sound and impact energy
with reduced morphological defects for better performance. The
absorption. Metallic foams are excellent impact energy absorber,
blowing agent used for foaming decomposes in molten aluminum
and they can convert impact energy into deformation energy
and generates gas bubbles therein. However, to have a uniformity
and absorb more energy than bulk metals at low stresses [4,6].
in structure, it should generate the desired amount of gas bubbles
Main application of particle reinforced metallic composite foams
of desired sizes during the foaming process. Apart from this the
is in defence and is used as passive safety systems due to energy
molten aluminum must possess a certain viscosity which is
absorption and dissipation properties of the foams. Both physical
affected by the addition of ceramics particles so that the
and mechanical properties of aluminum composite foams are not
generated gas bubbles are retained in the aluminum matrix during
only controlled by composition of matrix and reinforcement but
solidification [8]. In this entire process, temperature plays an
are also significantly affected by cell structure of foam [6]. Ma and
important role.
Song [5] found that the Cell structure of aluminum foams can be
Role of reinforcement of SiC on foam stability has been studied
by Prakash et al. [1] and also by Deqing and Ziyuan [9]. They have
controlled the stability of aluminum foam with the distribution of
∗ Corresponding author. Tel.: +91 1752393130; fax: +91 1752393005. SiC particles and the addition of higher content of SiC, increase the
E-mail address: oppandey@thapar.edu (O.P. Pandey). brittleness nature of foam [9]. Mukherjee et al. [10] have studied
the affect of SiC on the microstructure, density, and strength of
closed
Please cite this article in press as: Kumar S, Pandey OP. Role of fine size zircon sand ceramic particle on controlling the cell morphology
of aluminum composite foams. J Manuf Process (2015), http://dx.doi.org/10.1016/j.jmapro.2015.08.006
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http://dx.doi.org/10.1016/j.jmapro.2015.08.006
1526-6125/© 2015 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
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2 S. Kumar, O.P. Pandey / Journal of Manufacturing Processes xxx (2015) xxx–xxx
Table 1
Composition of the LM13 alloy in wt.%.
LM13 alloy Si Fe Cu Mn Mg Zn Ti Ni Pb Sn Al
wt.% 11.8 0.3 1.2 0.4 0.9 0.2 0.02 0.9 0.02 0.005 Balance
cell foams using CaCO3 as foaming agent. The stability of foam gen- Table 3
erally depends on the wettability of ceramic particles along the List of parameters of the developed metal foams.
cell walls and nodes. The position of particles depends on the gas
List of parameters of the development of metal foams
pressure inside the bubble and viscosity of melt alloy which vary ◦
Temperature at the time of addition 750 C
with foaming temperature. For a liquid foam to become stable, the of zircon sand
liquid–gas interface must be altered either by introducing a surfac- Temperature at the time of addition
800 C
◦
tant that reduces surface tension or by increasing the viscosity of of blowing agent
◦ ◦ ◦
the surface layer [5]. Foaming temperature 850 C, 875 C and 900 C
Particle size of zircon sand 1–25 µm
Few literatures are available on the effect of foaming temper- Particle size of blowing agent 1–25 µm and 50–100 µm
ature on the microstructure of the alloy foam [8,9]. It is reported No. of blades in stirrer 3
◦
that in case of alloy foam, the porosity increases with increases in Blade angles of stirrer 45
foaming temperature [11,12]. However, in case of composite foam, RPM of stirrer 630
Height of the stirrer in the melt 2/3 Inside the melt
the microstructure is hardly affected due to addition of ceramic
particles in the melt alloy [13–15]. The fracture resistance and
damage tolerance of foamed parts can be significantly improved composite foams. Before charging, the blowing agent (CaCO3) and
with non-metallic reinforcement onto the foam surface. Moreover, ◦
zircon sand particles were preheated at 300 C to remove moisture
a comparative study on the microstructure of the alloy foam and and other volatile substances. The composite foam was made by
the corresponding composite foam which is affected by increase stir casting route. For preparing the foam, the required quantity of
in the foaming temperature is not available. The microstructure is LM13 alloy was taken in a graphite crucible and melted in an
controlled by the process variables such as foaming temperature, electric furnace. The temperature of melt was raised to 750 C.
◦
foaming agent, impeller design, impeller speed, size and volume This molten mass was stirred using a graphite impeller at a
fraction of the solid particles during the foam making process. To speed of 630 rpm to create the vortex. After the formation of
the best of our knowledge, till date no work is reported describing vortex in the melt, blowing agent CaCO3 was added. However, for
the role of reinforcement of fine size ceramic particles on control- composite foam the zircon sand particles were charged inside
ling the cell morphology of aluminum composite foams at different the vortex first at the rate of 15–20 g/min. After the addition of
foaming temperatures. The present study is aimed to investigate the ceramic particles, the blowing agent was added into the molten
the influence of fine size zircon sand ceramic particles on the cell metal. To get uniform dispersion of blowing agent particles, the
morphology of LM13 alloy composite foam at different foaming molten metal was stirred quickly by increasing the speed of
temperatures using different size of CaCO 3 powders as blowing impeller up to 650 rpm. The furnace temperature was also
agent. In this present study, the porosity and foam quality has
increased and maintained at the desired temperature for 5 min to
been optimized to minimize the imperfections. The role of zircon
allow CaCO3 to decompose. The released gas forms bubbles. The
sand particles as reinforcing agent on stabilizing the foam has been
foamed melt was removed from the furnace and cooled in air.
studied and compared with the obtained structure.
Table 3 shows the list of processing parameters for the
development of foam. Specimens from different parts of the alloy
Experimental details × ×
2. foam as well as composite foam of 12 12 50 mm 3 were cut by
diamond cutter. These specimens were further ground on 400 up
In the present work, Al–Si alloy (LM13 piston alloy) of near to 800 grit papers and then polished with 0.5 µm diamond
eutectic composition is used as matrix material for the develop- polishing paste and etched by Keller’s reagent for microstructure
ment of foam. Fine grade blowing agent (CaCO3) was obtained analysis. The density of the prepared composite foams was mea-
from S D Fine-Chem Limited, Mumbai (India). Zircon sand was sured using Archimedes principle. The density of a foam material
obtained from Indian Rare Earths Ltd Mumbai. The procured sand is measured as mass per unit volume, which excludes all voids or
was sieved with AS 200 RETSCH analytical vibratory sieve shaker. pores. A common way to measure the density of a closed cell foam
Particles below 25 µm were used in the present work. The dis- material is based on Archimedes principle, which states that a
tribution of particles within the selected size range for blowing body submerged in a fluid will be buoyed up by a force equal to the
agent (CaCO3) and zircon sand was further analyzed with the help weight of the fluid it displaces. Density (p) measurement of the
of CAMSIZER XT. 2 wt.% CaCO 3 of particle size range 1–25 µm and foam was carried out on the LM13 alloy foam and reinforced LM13
50–100 µm of sample-1 and sample-2, respectively, were used as composite foam samples using the Archimedes principle as given
blowing agent. 5 wt.% zircon sand (ZrSiO4) of particle size range below.
(1–25 µm) is used as reinforcement. LM13 alloy was obtained in m
the form of ingots. The chemical compositions of LM13 alloy and p p (1)
=m − mw w
zircon sand were done by wet chemical method, which is given
in Tables 1 and 2, respectively. Addition of zircon sand (1–25 µm) where m is the mass of the foam sample in air, mw is the mass of
was done to improve the mechanical properties of the LM13 alloy the same foam sample in distilled water and pw is the density of
the distilled water.
Table 2
Composition of the zircon sand (ZrSiO4 ). 3. Results and discussion
Elements ZrO2 SiO2 TiO2 Fe2 O3

3.1. Role of particle size and shape on the decomposition rate
% in Bulk 65.30 32.80 0.27 0.12 of blowing agent
The particle size distribution of the blowing agent (CaCO3) and

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reinforced zircon sand particles was measured with the
help of
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S. Kumar, O.P. Pandey / Journal of Manufacturing Processes xxx (2015) xxx–xxx 3
100 100
Sample-1 Sample-2
90
80 80
70
round
60 60
Percentage by
Percentage by
50
40 40
30
20 20
10 non round
0
0
0 1-5 5-10 10-20 >20- 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Particle size range (m) Particle size (b/l)
Fig. 1. Graph showing particle size of sample-1 (blowing agent CaCO3 ) measured Fig. 4. Graph showing particle shape (breadth-to-length ratio) analysis graph of
sample-2 (blowing agent CaCO3 ) measured with CAMSIZER XT.
with CAMSIZER XT.
50
ZrSiO4 (Reinforcement)
40
30
Percentage by
20
10
0
1-
5 50-10 10-15 15-20 20-25 25-30
Particle size range (m)

Fig. 2. Graph showing particle shape (breadth-to-length ratio) analysis of sample-1
(blowing agent CaCO3 ) measured with CAMSIZER XT. Fig. 5. Graph showing particle size of zircon sand particle reinforcement
measured with CAMSIZER XT.
CAMSIZER XT and is shown in Figs. 1–4 for CaCO3 and for zircon
sand in Figs. 5 and 6. Blowing agent of the range 1–25 µm and 50– elongated particles. Zircon sand particles used as reinforcement in
100 µm for sample-1 (Figs. 1 and 2) and sample-2 (Figs. 3 and 4), the size range of 1–25 µm contains 40% particles having size range
respectively, were used. Simultaneously the shape of particles was 1–5 µm and 55% are of size range 11–25 µm. It is observed from
detected with the parameters describing the aspect ratio, i.e. width Fig. 6 that approximately 10% of zircon sand particles (with b/l ratio
over length (b/l), the sphericity and the symmetry. Figs. 2 and 4 <0.6) are elongated and 80% are asymmetrical/non round (with b/l
show that 37% of sample-1 and 45% of sample-2 (blowing agent ratio 0.6 to 0.9) and only 10% samples (with b/l ratio >0.9) are spher-
CaCO3) have an aspect ratio smaller than or equal to 0.9, which ical. This variation in shape is true for all samples with in an error of
are nearly spherical. 61% of sample-1 and 52% of sample-2 5%. Decomposition rate of blowing agent CaCO3 is very important
±
particle have aspect ratio from 0.6 to 0.9 which means these are factor during the development of foam. The decomposition rate of
triangular or asymmetrical particles. 2% of sample-1 and 3% of CaCO3 depends on many factors such as temperature, holding time,
sample-2 particles have aspect ratio of less than 0.6 which means atmospheric pressure, particle size and shape. Decomposition rate
these are is increased with the decrease the particle size [16]. The sample-1
100
Sample-2
100
90
90
80
80
70 round
70
60
60
Percentage by
50
Percentage by
50
40
40
30
30
20
20
10
10
non round
0
0
0 1-50 50-100 100-150 150-200 200-250 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Particle Shape (b/l)
Particle size range (m)
Fig. 3. Graph showing particle size of sample-2 (blowing agent CaCO3 ) measured Fig. 6. Graph showing particle shape of zircon sand particle reinforcement mea-
with CAMSIZER XT. sured with CAMSIZER XT.
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◦
with smallest particle size exhibits to have maximum decomposi- thinner cell faces at 850 C
tion rate in comparison to the sample-2 with larger particle sizes
as it depends on the surface area of the particles. Smaller particle
size tends to have large surface area that contributes to high
efficiency of heat transfer. It can accelerate the process by
reducing the thermal or heat resistance and other resistances such
as mass transfer or gas diffusion [17]. The cause of CO2 partial
pressure can be neglected in this study as the process was
◦
conducted at 850–900 C and at this temperature the pressure is
considered to be in equilibrium or atmospheric pressure [18].
3.2. Structural analysis of LM13 alloy foam prepared at

different foaming temperatures
3.2.1. Effect on cell size morphology

The macrographs of LM13 alloy foams which were produced at
different foaming temperatures are shown in Fig. 7. It reveals wide
variation in cell structure with variation in foaming temperature.
As a result, the density, foaming efficiency, average cell size and
cell wall thickness of LM13 alloy foam changed as foaming
temperature was increased. Table 4 gives the change in the
structural parameters of LM13 alloy foam developed at different
foaming temperature.
◦
Fig. 7a shows the structure of foam developed at 850 C. It
depicts nearly uniform cell size, small size of node with large
ligament length. At this foaming temperature, there is nearly no
bubble-free zone, coarsening cell structure, and unfavorable curva-
ture in the alloy foam. Since the particle size of CaCO3 powder is
fine and has narrow range of size distribution so it is easily
◦
decomposed into calcium oxide and carbon dioxide at 850 C. At
this temperature, the equilibrium presence of carbon dioxide gas
increases due to the decrement in viscosity of the alloy [1] which is
sufficient enough for the foaming. The released carbon dioxide gas
accelerates and moves upwards, which causes bubble coalescence
very rapidly. The uniformity of final bubble size and the total
volume of porosity related to the carbon dioxide gas content in
the melt alloy are determined by the growth rate between a bubble
and solid–liquid interface [3].
Fig. 7b shows the resultant morphology of regularly shaped cells
◦
as well as the overgrowth of some of the cells at 875 C foaming
temperature. As the temperature is increased the gas pressure also
increases. Formation of these cells is due to the uniform growth
as well as overgrowth of gas bubbles due to higher pressure. The
◦
cell diameter decreases steeply above 850 C. Foaming tempera-
ture directly affects the surface tension of melt and the foaming
agent decomposition. Such a high decomposition rate is not
desired, because the excess gas released from the melt leads to the
production of irregularly shaped cells and overgrowth of some
cells of foamed aluminum [12]. These cells even got
interconnected as marked by dotted line arrow in Fig. 7b and also
overgrowth as encircled.
◦
Further increment in the foaming temperature from 875 C to
◦
900 C has led to rapid generation of carbon dioxide gas.
Moreover, the viscosity also decreased. The liquid film becomes
thin. Con- sequently most of the air bubbles formed in the melt
was larger in size and unstable. As they proceed upwards the top
liquid pressure decreases and the bubble burst on reaching at the
melt surface [13]. The cell wall becomes weak and collapses with
high pressure. The excess released gas escaping through the melt
results in low foaming efficiency [14,15]. This results in a total
collapse of the foamed structure and ultimately generates closely
packed bubble like structure of the foam having thicker walls as
◦
shown in Fig. 7c. The structural analysis indicates that 850 C
foaming temperature is optimum. The microstructure of the
alloy foams was analyzed in terms of cell size distribution as
determined by optical micrograph which is shown in Fig. 7d. The
most notable structural feature of alloy foam is cell size and
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◦
which has been shown by dotted line in the micrograph. Since 875 C) leads to increased in the cell size of the LM13 alloy com-
most of the CaCO3 particles are spherical and triangular type so posite foam as the viscosity of melt decreased which is shown in
release of the CO2 gas in uniform throughout the melt. This Fig. 9b. Two neighboring bubbles in the melt are separated by a
leads to development of uniform size cellular structure.
3.2.2. Effect on cell wall thickness

The densities of the tested composite foams varied in the
range of 0.6–0.9 g/cm3. The density ratio of the foam and fully
dense composite has been used to describe the features of
foam. The density of the fully dense composite was taken as
2.88 g/cm3. Most of the cells in the foams observed are closed,
and the mean cell sizes of the foams display some difference
depending on the level of porosity. In order to have a close
view of foaming temperature on the cell wall thickness, node
size and ligament length of the LM13 alloy foams different
areas of foam was analyzed critically. A represen- tative
structure is also shown in Fig. 8a–c. Node size and ligament
length of the LM13 alloy foam decreased but cell wall thickness
◦
increased with the increasing temperature from 850 C to 900
◦ ◦
C. At 850 C cell wall thickness, node size and ligament length
of the LM13 alloy foams is as shown in Fig. 8a. At this foaming
temperature, alloy slurry is of lower viscosity. As a
consequence, balance between gas pressure and the surface
tension helps in the easier drawing of liquid material to cell
wall intersections that causes the thinner cell walls. With the
◦ ◦
change of temperature from 850 C to 875 C, cell size, node
size and ligament length of the LM13 alloy foams is decreased
due to the increase in the temperature because of decrease in
viscosity [8,13]. The higher rate of gas release into the melt
breaks the cell walls and allows the collapse of smaller cells
and formation of bigger cells on the surface of the melt as can
be observed in Fig. 8b where two sizes of cells are visible. At
◦
900 C the cell wall thickness of the sample foam is increased
but cell size, node size and ligament length decreases with
◦ ◦
increase in the temperature from 875 C to 900 C, as shown
in Fig. 8c. The phenomenon of collapsing observed at this
temperature is on higher side as shown in circle in Fig. 8c. Fig.
8d shows the optical micrograph of foam prepared at
◦
temperature 850 C. The air trapped in the liquid foam at the
increased temperatures is responsible for the cell size reduc-
tion due to its more expansion which makes the cell wall
larger. However, the increase in the cell wall thickness is
caused mainly due to increase in the viscosity of the LM13
alloy melt. Moreover, at certain areas it leads to rapture of cell
wall also (Fig. 8d).
3.3. Structural analysis of ceramic particle reinforced

composite foam at different foaming temperatures
3.3.1. Effect on cell size morphology

Fig. 9 shows the microstructure of composite foam
◦ ◦
prepared at different foaming temperatures (850 C, 875 C
◦ ◦
and 900 C). At 850 C, addition of 5 wt.% ceramic particle in
the melt alloy, increases the viscosity of the melt. At this
condition, the pressure of released gas during
decomposition of the CaCO3 is lower as compared to in base
LM13 alloy. This gas expands in the liquid metal and
creates bubble like structure on the surface of the melt,
forming liquid foam which is stabilized by the presence of solid
ceramic particles on the gas liquid interfaces of the cell walls
[14,15]. Table 5 gives the variation in the structural
parameters of LM13/Zr composite foam developed at different
foaming temperatures. The cell size of the LM13 alloy
composite foam is decreased with decreasing pressure of
released gas and increasing viscosity of melt which is shown
◦
in Fig. 9a. At 850 C, 2 wt.% blowing agent with 5 wt.% ceramic
particles did not produce sufficient pressure for making
uniform cell size composite foam (Fig. 9a). It is worth noting
◦
that the increment in the foaming temperature (from 850 C to
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Fig. 7. Macroscopic images of aluminum alloy foam with 2 wt.% blowing agent CaCO3 (sample-1) at (a) 850 ◦C, (b) 875 ◦C (c) 900 ◦C and (d) optical image of aluminum alloy
◦
foam 850 C.
Table 4
Effect of the foaming temperature on the cell parameters of LM13 alloy foam evolved with fine size blowing agent (sample-1).
◦
LM13 alloy foam Foaming temperature ( C) Density (g/cm3 ) Average cell size (mm) Average cell wall thickness (µm) Average ligament length (mm)
Sample-A 850 0.62 0.62 150 0.40

Sample-B 875 0.69 0.69 200 0.25
Sample-C 900 0.90 0.90 300 0.15
Standard deviation 0.145 0.629 76.376 0.125

Standard deviation mean 0.736 3.083 216.666 0.266
liquid film in the liquid foam. The liquid film tends to flow due to
followed by upcoming gas. It is interesting to note that fluid
surface tension [16]. Evidently, the node size, and ligament length
follows the counter and as per Coanda effect [20] so this type of
of both are increased with the increase in cell size [19]. Further-
distribution is possible. This may lead to variation in cell size,
more, the change of the foaming temperature seems to have less
node size and ligament length of the LM13 alloy composite
effect on the ligament length and node size than on cell size of the
foams. In the presence of the ZrSiO 4 particles the produced liquid
aluminum cells. The results indicate that the gas flow rate changes
foam becomes stable so the structure can be easily manipulated.
the cell size because of addition of ceramic particles. Considering ◦
With increasing in foaming temperature (900 C), the rate of
the fact that size of ceramic particles varies so they may occupy
decomposition of CaCO3 becomes higher so the equilibrium carbon
the area on cell walls and also at triple point (node). Since fine
dioxide gas pressure also increases. Due to decrement in the
size particles can be easily dragged by upcoming gas so they may
viscosity of the alloy melt and increment in the decomposition
occupy the cell wall area and bigger size particles may move
rate of blowing agent the cell formation becomes easier [1,13].
toward the corner because of their heavy size and also because of
This is responsible to generate uniform cell size for stable
contours
foaming of the composite slurry
Table 5
Effect of the foaming temperature on the cell parameters of LM13/5 wt.%Zr composite foam evolved with fine size blowing agent (sample-1).
◦
LM13 alloy foam Foaming temperature ( C) Density (g/cm3 ) Average cell size (mm) Average cell wall thickness (µm) Average ligament length (mm)
Sample-D 850 0.65 3.0 175 0.35

Sample-E 875 0.86 3.6 325 1.2
Sample-F 900 0.80 3.2 250 0.75
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Fig. 8. Macroscopic image of 2 wt.% CaCO3 (sample-1) showing variation in cell wall thickness and node size of the aluminum foams processed at (a) 850 ◦C, (b) 875 ◦C, (c)
◦ ◦
900 C and (d) optical image of cell ligament length aluminum alloy foam at 850 C showing rapture of cell wall with variation in thickness.
Fig. 9. Macroscopic images of aluminum composite foam with 2 wt.% blowing agent CaCO3 (sample-1) at (a) 850 ◦C, (b) 875 ◦C, (c) 900 ◦C and (d) optical image of aluminum
◦
composite foam at 900 C.
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Fig. 10. Macroscopic image of 2 wt.% CaCO3 (sample-1) showing variation in cell wall thickness and node size of the aluminum composite foams processed at (a) 850 ◦C, (b)
◦ ◦ ◦
875 C, (c) 900 C and (d) optical image of cell ligament length aluminum composite foam at 900 C.
(Fig. 9c). The wettability of the ceramic particles by the alloy melt as a liquid flow barrier from the cell wall toward the plateau
is not the only dominating factor but also to provide the stability border [15,19]. The retardation in cell wall drainage, results the
for the foam which is greatly dependent on the drainage and increment in cell wall thickness. Therefore, it can be said that the
◦ ◦
rupture of the cell wall separating the gas bubbles. The role of the increase in foaming temperature from 875 C to 900 C during the
particles on the drainage and rupture process affects the foam preparation of the LM13 alloy composite foams has a great effect
stability. The higher viscosity is responsible to slow down the on the cell size. Fig. 10a–d shows the cell wall thickness and node
liquid flow which retards the cell wall drainage before it solidifies size of the LM13 alloy composite foams prepared with different
during the addition of ceramics particles in the alloy melt [13]. foaming temperature. The effect of the higher rate of gas release
Apart from their effect on melt viscosity, the ceramic particles at 2 wt.% CaCO3 on cell wall thickness and node size are shown in
have an important impact on foam stability through their Fig. 10c where the cell size, cell wall thickness and node size are
attachment to the gas–liquid interface, which changes the decreased due to the excess of gas released by blowing agent
interfacial curvatures and reduces the capillary pressure because at this condition the viscosity of melt is decreased. The
difference between the plateau border and the cell wall of the thinner cell wall and node size in contrast with higher rate of gas
◦
aluminum composite foam. It is apparent from the micro- release at 900 C with 2 wt.% CaCO3 is observed in Fig. 10c as
◦ ◦
structures of the produced foams that the cell size and cell wall compared to other foaming temperature (850 C and 875 C).
thickness of the ZrSiO 4 based foams is significantly smaller which However, the decrease in the cell wall thickness is caused mainly
is shown in Fig. 9d. The distance between cell to cell, shape and by decreasing the viscosity of the composite slurry due to higher
◦
size of cell is clearly shown in optical micrographs of composite foaming temperature. At 850 C foaming temperature, the node
◦
foam at 850 C. size of the cell is larger. The foam does not coalesce to form a
bigger bubble even it comes into contact with other foam during
3.3.2. Effect on cell wall thickness its floatation to the surface of the melt due to lower viscosity.
The cell size of the LM13 alloy composite foam got increased Higher rate of release of gas may cause its colli- sion. In turn it may
with increasing rate of CO2 release which is dependent on the also help in raising the ceramic particle upwards and ultimately to
◦
decomposition rate of CaCO3. At 850 C foaming temperature, the cell walls [21]. In addition, the cell uniformity as well as cell size,
2 wt.% CaCO3 foaming agent results in a much smaller cell size node and structure are also important factors determining the
◦
in comparison to the larger cell size produced at 875 C foaming properties of foam. The characteristics of cell may be quite
temperature as can be seen in Fig. 10a and b. The increase in the different in foam metals produced by different processes, thus
◦
thickness of the cell wall at foaming temperature of 875 C with resulting in different mechanical properties. Therefore, it is not
addition of ceramic particles implies that the viscosity of the com- suitable to compare the data of mechanical properties for foams
posite melt is becoming higher. Moreover, the increase in cell wall obtained by different process, even for the same cell wall material.
thickness also means that more aggregation of particles in the The mechanical properties of foam materials are related not only
particle–liquid creates a more tortuous path for the liquid and acts to the properties of cell wall material but also the cell geometry.
G Model
Fig. 11. Macroscopic images of aluminum composite foam with 2 wt.% blowing agent CaCO3 (sample-2) at (a) 850 ◦C, (b) 875 ◦C, (c) 900 ◦C and SEM image of 900 ◦C.
The improvement in the cell geometry, such as node size, ligament interruption during foaming
length, cell uniformity and distribution (Tables 4 and 5), may lead
to improvement in the mechanical properties [1].
The experimental results show that the increase in foaming
temperature with addition of ceramic particles in LM13 alloy
composite foams decreases the cell wall thickness. These
experimental results indicate that foaming temperature on
decomposition rate of blowing agent is responsible to change the
morphology and structure of the closed cell composite foams.
3.3.3. Structural analysis of composite foam with different

size and shape of blowing agent
Due to dependency of the particle size of blowing agent and
temperature on decomposition rate of blowing agent, the bubble
formation was optimized. Structural feature of foam obtained from
higher particle size of foaming agent is shown in Fig. 11. Table 6
gives the variation in the structural parameters of LM13/5 wt.% Zr
composite foam developed at different size and shape of blowing
agent. The gas bubbles could float toward the melt surface where
◦
liquid aluminum foam is generated. At 850 C, decomposition
rate
decreases when particle sizes of blowing agent increases [16]. The
◦
foaming temperature was kept around 850 C. At this temperature,
the pressure and flow rate of the blowing gas is not sufficient for
the formation of uniform pore size in liquid aluminum, which is
shown in Fig. 11a. The pressure and flow rate of gas in liquid
aluminum depends on the viscosity of liquid, surface tension,
feeding rate of blowing agent, and its particle size and amount.
◦
When the foaming temperature was increased from 850 C to 875
◦
C, decomposition rate of blowing agent increases and viscosity
of the melt material decreases. The pressure and flow rate of
gas also increases. At this particular temperature, middle
expansion, maximum expansion and cell collapsing can create an
G Model
process. It is clear that the foaming temperature as well as size
of blowing agent affect the foam expansion and cell structure
◦
[19]. Aluminum composite foam at low temperature (850 C)
as shown in Fig. 11a, exhibits the presence of a very thick cell
wall of composite foam which is observed due to a very low
level of expansion because the decomposition rate of coarse
size of blowing agent is low. The coarse size blowing agent
generates typical elongated structure in normal expansion and
◦
collapse processes at 875 C. A large number of small cells
grow and coalesce to form a few large cells as can be seen in
Fig. 11b. The maximum expansion of composite foam
occurred due to the high decomposition rate of blowing agent,
◦
less viscosity and less surface tension of liquid at 900 C, which
is shown in Fig. 11c. At this temperature, the cell face thin-
ning has occurred which is a consequence of a capillarity-
driven melt flow from the ligament length to cell node. The
average cell size of composite foams is similar, as shown in Fig.
11d. The maximum expansion of the composite foam was not
achieved. The composite foams have higher number of circular
pores than the pure Al foams, as shown in Fig. 11d, indicating
more uniform cell structure of the composite foams. The
improvement in foam structure is obtained by the increment
in viscosity and surface tension, due to the presence of zircon
sand particles in ligament length and cell walls that leads to a
reduction in the rate of drainage and cell coalescence. The cell
face can either rupture when a critical cell face thickness is
reached or the drainage process can cease when other forces,
opposing the flow, operate in the cell face material. The
experimental results clearly show that roll of particles size and
shape can have a pronounced stabilizing effect on the metal
foam and composite foam structure evolution. This is
especially likely be the case when the particle size of blowing
agent is changed. All the structural parameters are affected by
the change in the particle size of blowing agent, foaming
temperature and addition of
G Model
Table 6
Effect of the foaming temperature on the cell parameters of LM13/5 wt.% Zr composite foam evolved with coarse size blowing agent (sample-2).
◦
LM13 alloy foam Foaming temperature ( C) Density (g/cm3 ) Average cell Average cell wall Average ligament
size (mm) thickness (µm) length(mm)
Sample-G 850 0.78 3.6 285 1.55

Sample-H 875 0.89 3.1 255 1.1
Sample-I 900 0.92 3.0 170 0.90

ceramics particle as reinforcement. It should be noted that the cell Acknowledgments

face thinning rate is further accelerated by face stretching in foams
experiencing expansion during increase foaming temperature. The The authors are thankful to Armament Research Board (ARM-
main parameters controlling the evolution are the melt viscosity REB), Terminal Ballistics Research Laboratory (TBRL), Defence
and surface tension, processing time (both melt foaming and solid- Research and Development Organization (DRDO), India for provid-
ification), type of particles and their interaction with a liquid ing financial support under the letter no. ARMREB
metal. It has been highlighted in this work that a complex CDSW/2012/148 for this study.
approach is required for the optimization of these parameters to
produce a synergistic contribution allowing better control of the References
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Journal of Manufacturing Processes

Article in Journal of Manufacturing Processes · September 2015

Tribological behaviour of Al composite View project

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Journal of Manufacturing Processes

Elements ZrO2 SiO2 TiO2 Fe2 O3

The particle size distribution of the blowing agent (CaCO3) and

Particle size range (m)

3.2. Structural analysis of LM13 alloy foam prepared at

3.2.1. Effect on cell size morphology

3.2.2. Effect on cell wall thickness

3.3. Structural analysis of ceramic particle reinforced

3.3.1. Effect on cell size morphology

Sample-A 850 0.62 0.62 150 0.40

Standard deviation 0.145 0.629 76.376 0.125

Sample-D 850 0.65 3.0 175 0.35

Standard deviation 0.108 0.305 75.00 0.425

3.3.3. Structural analysis of composite foam with different

Sample-G 850 0.78 3.6 285 1.55

Standard deviation 0.073 0.321 59.651 0.332

ceramics particle as reinforcement. It should be noted that the cell Acknowledgments

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