Surpassing the Theoretical Limit of Porosity in Conventional Solid-State Foaming: Microstructure Characterization of Length Scales in a Copper Metal Foam

Report No. ARL-TR-7139
Authors: Mark A Tschopp; Kris A Darling; Mark A Atwater;
Date/Pages: November 2014; 60 pages
Abstract: Solid-state processes for creating metal foams are often complex and/or time consuming, and in methods such as gas entrapment, there are practical limits to the porosity achievable due to pore coalescence and percolation. A simple process has been developed to create copper-based metal foam with porosity greater than 65%. The process is unique as expansion occurs within particles, not between them. The method is applied to create a bulk part. The microstructure length scales of the foamed particles are examined using 1- and 2-point microstructure statistics.
Distribution: Approved for public release
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Last Update / Reviewed: November 1, 2014