Manufacturing process of syntactic foam

 Generally, syntactic foams are created by combining rigid, hollow spheres of glass,
ceramic, polymer or metal (called microballoons or hollow microspheres) in a polymer,
metal or ceramic matrix.
 Thermoplastic and thermosetting polymers have been employed to process syntactic
foam.
 Examples of thermoplastic resin matrices: polyethylene, polypropylene, polystyrene
and nylon.
 Examples of metal: aluminium, titanium and iron
 Examples of ceramic matrices: silicon carbide, carbon, alumina, and silicon nitride.
 Microballoons are available in variety of sizes and material including glass
microspheres, carbon and polymer.
General methods for preparation syntactic foams
• The methods require the use of at least two chemical constituents; one to
decompose into a gas to form bubbles, other one to form cell walls.
• Generally, the industries process the syntactic foams by infiltration
process using Infiltration chamber.

Figure 1 Schematic diagram of Infiltration

chamber
Steps followed in Infiltration process

Pouring microballoons into half

Coat the inner surface of mold Place a layer of metal, ceramic or
the height of mold, gentle
(e.g graphite) for easy removal of resin for separating
tapping and knocking to get
specimen. microballoons and matrix.
randomly closed pack structure.

Remove the mold after complete

Place the mold into infiltration
Ensure proper heating solidification and water cooled to
chamber.
room temperature.
Advantages of syntactic foams
Advantage

 Provide strength and structural integrity at low density

 The toughened microscope matrix provide stiffness and impact/shock resistant
properties

 Syntactic foams consist more than 50% porosity due to the use of hollow fillers,
substantial weight savings are gained.

 The foams provide buoyancy resulting the materials is suitable for marine
products
Reference

Bisht, A., & Gangil, B. (2017). Processing of syntactic foams: A review.

International Advanced Research Journal in Science, Engineering and
Technology, 303, 66-70.

Orbulov, I., & Ginsztler, J. (2012). Compressive characteristics of metal

matrix syntactic foams. Composites: Part A, 43, 553-561.