• Korean Journal of Materials Research
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• v.24 no.8
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• pp.393-400
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• 2014

NiO catalysts were successfully coated onto FeCrAl metal alloy foam as a catalyst support via a dip-coating method. To demonstrate the optimum amount of NiO catalyst on the FeCrAl metal alloy foam, the molar concentration of the Ni precursor in a coating solution was controlled, with five different amounts of 0.4 M, 0.6 M, 0.8 M, 1.0 M, and 1.2 M for a dip-coating process. The structural, morphological, and chemical bonding properties of the NiO-catalyst-coated FeCrAl metal alloy foam samples were assessed by means of field-emission scanning electron microscopy(FESEM), scanning electron microscopy-energy dispersive spectroscopy(SEM-EDS), X-ray diffraction(XRD), and X-ray photoelectron spectroscopy(XPS). In particular, when the FeCrAl metal alloy foam samples were coated using a coating solution with a 0.8 M Ni precursor, well-dispersed NiO catalysts on the FeCrAl metal alloy foam compared to the other samples were confirmed. Also, the XPS results exhibited the chemical bonding states of the NiO phases and the FeCrAl metal alloy foam. The results showed that a dip-coating method is one of best ways to coat well-dispersed NiO catalysts onto FeCrAl metal alloy foam.

• Journal of Powder Materials
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• v.17 no.6
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• pp.489-493
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• 2010

Nickel-based and iron-based alloys have been developed and commercialized for a wide range of high performance applications at severely corrosive and high temperature environment. This alloy foam has an outstanding performance which is predestinated for diesel particulate filters, heat exchangers, and catalyst support, noise absorbers, battery, fuel cell, and flame distributers in burners in chemical and automotive industry. Production of alloy foam starts from high-tech coating technology and heat treatment of transient liquid-phase sintering in the high temperature. These technology allow for preparation of a wide variety of foam compositions such as Ni, Cr, Al, Fe on various pore size of pure nickel foam or iron foam in order for tailoring material properties to a specific application.

• Journal of Korea Foundry Society
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• v.30 no.6
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• pp.217-223
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• 2010

Foamed metal has become an attractive material, which has unique physical, thermal, acoustic, damping and mechanical properties, because large amount of pores are distributed in the metal matrix. Therefore, metal foam can be used for the light weight application in automotive, locomotive, aerospace fields. Aluminum foams have been developed successfully and will be employed in the next generation of energy absorption boxes. Magnesium alloys are most eligible candidate to substitute aluminum alloy, especially for lower density and higher damping properties in wide industrial fields. Magnesium alloy foams are expected to be particularly advantageous due to two thirds the density of aluminum. However, foaming magnesium have been weakness of high activity, difficult processing and very dangerous. In order to upgrade this problem, AM50 magnesium alloy which has better characteristic is safe to use through foaming time and alloying element in this study.

• Korean Journal of Materials Research
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• v.21 no.6
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• pp.314-319
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• 2011

Melt foaming method is one of cost-effective methods to make metal foam and it has been successfully applied to fabricate Mg foams. In this research, AZ31 Mg alloy ingot was used as a metal matrix, using AlCa granular as thickening agent and $CaCO_3$ powder as foaming agent, AZ31 Mg alloy foams were fabricated by melt-foaming method at different foaming temperatures. The porosity was above 41.2%~73.3%, pore size was between 0.38~1.52 mm, and homogenous pore structures were obtained. Microstructure and mechanical properties of the AZ31 Mg alloy foams were investigated by optical microscopy, SEM and UTM. The results showed that pore structure and pore distribution were much better than those fabricated at lower temperatures. The compression behavior of the AZ31 Mg alloy foam behaved as typical porous materials. As the foaming temperature increased from $660^{\circ}C$ to $750^{\circ}C$, the compressed strength also increased. The AZ31 Mg alloy foam with a foaming temperature of $720^{\circ}C$ had the best energy absorption. The energy absorption value of Mg foam was 15.52 $MJ/m^3$ at a densification strain of 52%. Furthermore, the high energy absorption efficiencies of the AZ31 Mg alloy foam kept at about 0.85 in the plastic plateau region, which indicates that composite foam possess a high energy absorption characteristic, and the Vickers hardness of AZ31 Mg alloy foam decreased as the foaming temperature increased.

• Journal of Korea Foundry Society
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• v.30 no.6
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• pp.241-246
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• 2010

The viscosity of foam metal is necessary to get the pores, but it is difficult to manufacture net-shape foam, because the fluidity decreases by increasing viscosity. In this study, the A356 alloy which has good fluidity and less defect was selected and fabricated to foam metal. To understand about effect of thickening agent on foaming and mechanical properties, quantity of thickening agent was changed. The pore size, porosity and distribution of foam metal were measured by i-solution program. And compression test were performed by UTM. In case of 3.0wt% Ca in thickening agent, it is found that most of foam consist of homogeneous shape, and the growth height had the highest value of 204 mm in the all fabricated foams. The porosity was 93% and compressive strength was 3.1 MPa. In the microstructure, the $Al_2Si_2Ca$ intermetallic compound and Ti were observed. The vickers hardness value rose with increasing viscosity value.

• Korean Journal of Materials Research
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• v.22 no.6
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• pp.309-315
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• 2012

Metal foam has many excellent properties, such as light weight, incombustibility, good thermal insulation, sound absorption, energy absorption, and environmental friendliness. It has two types of macrostructure, a closed-cell foam with sealed pores and an open-cell foam with open pores. The open-cell foam has a complex macrostructure consisting of an interconnected network. It can be exploited as a degradable biomaterial and a heat exchanger material. In this paper, open cell Mg alloy foams have been produced by infiltrating molten Mg alloy into porous pre-forms, where granules facilitate porous material. The granules have suitable strength and excellent thermal stability. They are also inexpensive and easily move out from open-cell foamed Mg-Al alloy materials. When the melt casting process used an inert gas, the molten magnesium igniting is resolved easily. The effects of the preheating temperature of the filler particle mould, negative pressure, and granule size on the fluidity of the open cell Mg alloy foam were investigated. With the increased infiltration pressure, preheat temperature and granule sizes during casting process, the molten AZ31 alloy was high fluidity. The optimum casting temperature, preheating temperature of the filler particle mould, and negative pressure were $750^{\circ}C$, $400-500^{\circ}C$, and 5000-6000 Pa, respectively, At these conditions the AZ31 alloy had good fluidity and castability with the longest infiltration length, fewer defects, and a uniform pore structure.

• Journal of Korea Foundry Society
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• v.30 no.1
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• pp.22-28
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• 2010

Metal foam is a porous or cellular structure material and representative property is a very high porosity. Foamed materials have very special properties such as sound, vibration, energy and impact absorption capacity. Especially this properties are widely used for safety demands of architecture, auto and aircraft industry. But metal foam need to increased its compression strength and hardness. This study were researched about Al-Si alloy foams with variation amount of Si contents for their fabrication and properties such as porosity, cell structure, microstructure and mechanical properties. The result are that the range of pore size is 2~4 $mm{\phi}$, the high porosity are 88%, high yield strength is 1.8MPa, the strain ratio is 60~70% and vickers hardness is 33.1~50.6.

• Proceedings of the KSME Conference
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• 2004.04a
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• pp.382-387
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• 2004

Nanoindentation technique has been used to measure the mechanical properties of aluminium alloy foam cell walls. Al-Si-Cu-Mg alloy foams of different compositions and different cell morphologies were produced using powder metallurgical method. Cell morphology of the foam was controlled during production by varying foaming time and temperature. Mechanical properties such as hardness and Young's modulus were calculated using two different methods: a continuous stiffness measurement (CSM) and an unloading stiffness measurement (USM) method. Experimental results showed that hardness and Young's modulus of Al-5%(wt.)Si-4%Cu-4%Mg (544 alloy) precursor and foam walls are higher than those of Al-3%Si-2%Cu-2%Mg (322 alloy) precursor and foam walls. It was noticed that mechanical properties of cell wall are different from those of precursor materials.

• Korean Journal of Materials Research
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• v.27 no.7
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• pp.392-397
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• 2017

Fluorine-doped tin oxide (FTO) coated NiCrAl alloy foam is fabricated using ultrasonic spray pyrolysis deposition (USPD). To confirm the influence of the FTO layer on the NiCrAl alloy foam, we investigated the structural, chemical, and morphological properties and chemical resistance by using USPD to adjust the FTO coating time (12, 18, and 24 min). As a result, when an FTO layer was coated for 24 min on NiCrAl alloy foam, it was found to have an enhanced chemical resistance compared to those of the other samples. This improvement in the chemical resistance of using USPD NiAlCr alloy foam can be the result of the existence of an FTO layer, which can act as a protection layer between the NiAlCr alloy foam and the electrolyte and also the result of the increased thickness of the FTO layer, which enhances the diffusion length of the metal ion.

• Journal of Korea Foundry Society
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• v.31 no.3
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• pp.145-151
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• 2011

Metallic foam has been known as a functional material which can be used for absorption properties of energy and sound. The unique characteristics of Al foam of mechanical, acoustic, thermal properties depend on density, cell size distribution and cell size, and these characteristics expected to apply industry field. Al-Zn-Mg-Cu alloy foams was fabricated by following process; firstly melting the Al alloy, thickening process of addition of Ca granule to increased of viscosity, foaming process of addition of titanium hydride powder to make the pores, holding in the furnace to form of cooling down to the room temperature. Metal foams with various porosity level were manufactured by change the foaming temperature. Compressive strength of the Al alloy foams was 2 times higher at 88% porosity and 1.2 times higher at 92% porosity than pure Al foams. It's sound and vibration absorption coefficient were higher than pure Al foams and with increasing porosity.