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Manufacturing and characterization of open-cell stainless steel foams by investment casting

Wednesday (24.10.2018)
19:03 - 19:06
Part of:
- Poster Battery housings for electric vehicles using CFRP and aluminium foam 0 Joachim Baumeister
- Poster Manufacturing and characterization of open-cell stainless steel foams by investment casting 1 Jan Frömert
- Poster Interface formation of Mg2X (X = Si, Sn) in cellular Si infiltrated by Mg(Sn) alloys 1 Alexander M. Matz
- Poster Production of microcellular PMMA using the bead foaming technology 1 Mikel Mugica
- Poster Nanocellular PMMA with tunable cellular structure by changing the rheological behaviour of the polymer matrix. 1 Judith Martín de León
- Poster Production of thermoplastic polyurethane foams synthesized with different contents of hard segment and graphene nanoplatelets by the gas dissolution foaming process 1 Ph.D. Mercedes Santiago-Calvo
- Poster Surface functionalized filters for aluminum melt filtration 1 Dr.-Ing. Claudia Voigt
- Poster Nanocellular polymers based on PMMA/sepiolite nanocomposites: characterization of the mechanical behaviour 1 Victoria Bernardo
- Poster Impact resistant foams based on PP/POE blends 1 Ph.D. Santiago Munoz Pascual
- Poster Crosslinked open cell ethylene butyl acrylate copolymer (EBA) foams: properties and applications 1 Ph.D. Eduardo López
- Poster Influence of molecular weight in the solubility,diffusivity and the subsequent cellular structure of polystyrene foams 1 Ph.D. Alberto Ballesteros
- Poster Crushing strength measurement at reticulated ceramic foams ex situ and in situ CT analysis 1 Dr.-Ing. Claudia Voigt
- Poster Initiation of plateau region during compression test of porous metals with aligned unidirectional pores 1 Tomoya Tamai
- Poster Active meta-materials with adjustable pore size 1 Dr. Reza Hedayati
- Poster Polymeric foams 3D numerical mechanical modelling 1 Stefano Tagliabue
- Poster Characterisation of NiTi cellular materials fabricated by the powder-metallurgy spaceholder technique 1 Dr. Karl Dahm
- Poster Accurate separation of open cell metal foams using remote laser cutting technique 1 Robert Baumann
- Poster Generation of artificial foam structures and evaluation of their thermo-mechanical, flow and filtration characteristics (Poster) 1 Christoph Settgast
- Poster Surface modification of magnesium-based foams by Directed Plasma Nanosynthesis 1 Viviana Marcela Posada Pérez

General Topic P: Postersession
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Open-cell steel foams are potential candidates for a wide range of applications due to their combination of mechanical and physical-chemical properties. The open-cell structure exposes an increased surface area for interaction with fluids flowing through the foam. Applications of interest range from lightweight construction material and crash absorbers in the transportation sector to heat conducting components such as heat sinks. Most current research concerns the manufacturing of open-cell aluminum foams because they pose an obvious choice for lightweight construction and require less effort in production. Stainless steel foams expand the list of possible applications due to their higher strength and volumetric heat capacity. In contrast, reproducible manufacturing of open-cell steel foams is challenging because of higher melting temperatures, high viscosity of the melt and chemical reaction with the mold material.

This study presents a novel manufacturing process for open-cell stainless steel foams with pore densities of 10, 13 and 15 ppi using investment casting. The influence of microstructure on the mechanical properties under quasi-static compression (plateau stress, energy absorption and strain hardening) of an austenitic (AISI 304), a super duplex (AISI F55) and a martensitic stainless steel with metastable austenite (AISI 420) were investigated. Microstructure was characterized prior and subsequent to mechanical testing using light microscopy and SEM.

The manufacturing process yields open-cell foams with relative densities in the range of 10 - 20 %, solid struts being circular in shape and defect-free surfaces. Electro-polishing is used to further minimize the influence of near-surface deformation on the resulting microstructure, especially in steel samples containing metastable austenite. During compression, martensitic transformation of metastable austenite affects the strain hardening and leads to brittle fracture of single struts.

Jan Frömert
Pforzheim University of Applied Sciences
Additional Authors:
  • Tobias G. Lott
    Pforzheim University of Applied Sciences
  • Dr. Alexander M. Matz
    Pforzheim University of Applied Sciences
  • Prof. Dr. Norbert Jost
    Pforzheim University of Applied Sciences