The effect of alumina particles on the microstructural and mechanical properties of copper foams fabricated by space-holder method

The copper foam is an interesting field of research because of its several advantages as an engineering material. Powder metallurgy presents an alternative route to obtain a porous structure with high strength to weight ratio and functional properties. The viability of processing copper foam separately with two different space-holders such as ammonium hydrogen carbonate (NH₄HCO₃) and sodium chloride (NaCl) of 50 vol% was studied. The green compacts obtained under 200 MPa were sintered at different cycles for the complete removal of space-holder. The sintered foams were characterized by optical microscopy (OM), scanning electron microscopy (SEM) and uniaxial testing machine (UTM) to study their structural features and compressive strength, respectively. The results showed that NaCl particles were the best alternative to obtain a porous structure, hence two different sizes (1 and 0.01 μm) of alumina (Al₂O₃) particles with 2, 4 and 6 vol% were used to fabricate copper foams. As a result, a bimodal structure consisting of macro and micropores with a highly interconnected porosity was achieved. In addition, the smaller size alumina particles promoted a higher density of pores, however, the compressive strength was reduced for the higher volume fraction of alumina particles.