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Metals 2016, 6(5), 110; doi:10.3390/met6050110

Melt Processing and Characterization of Al-SiC Nanocomposite, Al, and Mg Foam Materials

1
Center of Excellence for Research in Engineering Materials (CEREM), Advanced Manufacturing Institute (AMI), King Saud University, P. O. Box 800, Riyadh 11421, Saudi Arabia
2
Mechanical Engineering Department, King Saud University, P.D. Box 800, Riyadh 11421, Saudi Arabia
3
Mechanical Design and Materials Department, Faculty of Energy Engineering, Aswan University, Aswan 81521, Egypt
4
Electrochemistry and Corrosion Laboratory, Department of Physical Chemistry, National Research Centre (NRC), Dokki, 12622 Cairo, Egypt
*
Author to whom correspondence should be addressed.
Academic Editor: Afsaneh Rabiei
Received: 4 March 2016 / Revised: 11 April 2016 / Accepted: 5 May 2016 / Published: 12 May 2016
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Abstract

In the present work, metallic foams of Al, Mg and an Al-SiC nanocomposite (MMNC) have been fabricated using a new manufacturing technique by employing melt infiltration assisted with an electromagnetic force. The aim of this investigation was to study and to develop a reliable manufacturing technique consisting of different types of metallic foams. In this technique, an electromagnetic force was used to assist the infiltration of Al-SiC slurry and of pure liquid metal into a leachable pattern of NaCl, thus providing perfect cellular structures with micro-sized porosities. A high frequency induction coil unit equipped with a vacuum chamber and a hydraulic press was used to manufacture the foam materials. Microstructures of the produced foam materials were explored by using Field Emission Scanning Electron Microscopy (FESEM). The mechanical behavior of the manufactured foams was investigated by applying compression testing. The results indicate a high applicability of the new technique in producing metallic foams of pure metals and of a metal matrix nanocomposite . The produced foam materials displayed isotropic cellular structures with excellent compressive behaviors. Microstructure measurements indicate that the average pore size and strut thickness that can be achieved are in the ranges of 100–500 μm and 50–100 μm, respectively. The produced foam of the Al-SiC nanocomposite material provided the highest strength of 50 MPa prior to the densification stage, which equates to 25 times, and 10 times higher than the strength levels that were obtained by Al, and Mg foams, respectively. View Full-Text
Keywords: manufacturing; metallic foam; nanocomposite; infiltration; electromagnetic stirring manufacturing; metallic foam; nanocomposite; infiltration; electromagnetic stirring
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Nabawy, A.M.; Khalil, K.A.; Al-Ahmari, A.M.; Sherif, E.-S.M. Melt Processing and Characterization of Al-SiC Nanocomposite, Al, and Mg Foam Materials. Metals 2016, 6, 110.

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