Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials &
p; Metallurgy
A study on development of open cell stainless steel foams produced
by pre -shaped cores using conventional melting technique
G.Sundarraju*, J.Anburaj** and S.S.Mohamed Nazirudeen***
Abstract- Metal foams are a new, as yet imperfectly
characterized, class of materials produced by several
methods of manufacturing technologies. The primary
characteristics of foam materials having a lower
densities as well as a improved novel properties
such as physical, mechanical, thermal, electrical and
acoustic . Metal foams offer significant performance
gains in the light weight, stiff structures for the
efficient absorption of energy, and perhaps for
acoustic control and other more specialized
applications, The properties of metal foams and other
cellular metal structures depend on the relative
density and cell topologies. In this paper involves the
technology for the development of stainless steel
foams using air induction melting furnace by pre-
shaped cores. The prepared stainless steel foams
were characterized by studying its hardness testing,
density measurement, microstructure analysis and
topology study by x-ray radiography testing. The
resultant pore shapes and properties of stainless steel
foams were noticeably revealed that a foam
component of stainless steel can be successfully made
using a cheapest method of induction melting
techniques.
Keywords: Open cell pores, stainless steel, pre-
shaped cores and induction melting
I. INTRODUCTION
Porous materials are defined as foam materials
purposely proceed in such a way contain abundant
void space. They are usually made up of metals or
Ceramics, They have engineered, Inter connected
porosity with relatively uniform pore distribution and
length of passages that are fabricated from metal
powder particles using powder metallurgy route or by
using liquid metal melting route.
The porous metallic materials such as foams metal
.metals with directional porosity, sponge like metals,
Structural cellular metals and sintered metals are
increasingly expected as prospective light weight
structural and functional materials with superior
damping, filtering and Sound absorbing properties.
-----------------------------------------------------------
*PG STUDENT, **LECTURER, ***PROFESSOR
Department of Metallurgical Engineering
PSG College of Technology, Coimbatore - 641004
(e-mail:sunmetly@gmail.com)
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The nine distinct process-routes have been
developed to make metal foams, of which five are
now established commercially. those in which the
foam is electrodeposited from an aqueous solution;
those which depend on liquid-state processing; and
those in which the foam is created in the solid state.
Each method can be used with a small subset of
metals to create a porous material with a limited
range of relative densities and cell sizes. Some
produce open-cell foams, others produce foams in
which the majority of the cells are closed.
Making metal foams
The properties of metal foam and other cellular
metal structures depend upon the properties of the
metal, the relative density and cell topology (e.g.
open or closed cell, cell size, etc.). Metal foams are
made by one of nine processes, listed below. Metals
which have been foamed by a given process are listed
in square brackets.
i). Bubbling gas through molten AlSic or AlAl2O3
alloys. [Al, Mg]
ii). By stirring a foaming agent (typically TiH2) into
a molten alloy and controlling the pressure while
cooling. [Al]
iii).Consolidation of a metal powder (aluminum
alloys are the most common
with a particulate foaming agent (TiH2 again)
followed by heating into the mushy state when the
foaming agent releases hydrogen, expanding the
material.
[Al, Zn, Fe, Pb, Au]
iv). Manufacture of a ceramic mold from a wax or
polymer-foam precursor, followed by burning-out of
the precursor and pressure infiltration with molten
metal or metal powder slurry which is then sintered.
[Al, Mg, NiCr, stainless steel, Cu]
v). Vapor phase deposition or electro deposition of
metal onto polymer foam
Precursor which is subsequently burned out, leaving
cell edges with hollow cores. [Ni, Ti]
vi). The trapping of high-pressure inert gas in pores
by powder hot isostatic pressing, followed by the
expansion of the gas at elevated temperature.[Ti]
vii). Sintering of hollow spheres, made by a modified
atomization process, or from metal-oxide or hydride
spheres followed by reduction or dehydridation, or by
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy
vapor-deposition of metal onto polymer spheres. [Ni,
Co, NiCr alloys]
viii). Co-pressing of a metal powder with a leachable
powder or pressure infiltration Of a bed of leachable
particles by a liquid metal, followed by leaching to
leave a metal-foam skeleton. [Al, with salt as the
leachable powder]
ix). Dissolution of gas (typically, hydrogen) in a
liquid metal under pressure, it to be released in a
controlled way during subsequent solidification.[Cu,
Ni, Al]
Only the first five of these are in commercial
production. Each method can be used with a small
subset of metals to create a porous material with a
limited range of relative densities and cell sizes.
To produce metal foams by melting route with
pre shaped cores is one of the new methods for
produce open cell metal foams; in this method
achieve 60-65%
Porosities.
2. EXPERIMENTAL PROCEDURE
a) Material selection
A-304 Stainless steel material is selected for
a given component because its property profile
matches that demanded application. The desired
property profile characterizes the application. It is
identified by examining the function of the
component.
A 304- Stainless steel (Equivalent cast
material is CF80)as per ASTM A351 is consist of
Chromium 18.5 %,Nickel 8.3%,
Manganese1.8%,Silica1 % ,Carbon 0.08% ,
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Phosphorous0.045%,Sulfur0.03%, Molybdenum
0.50%.
Porous parts are specified in stainless steel
to take special advantage of that metals excellent
resistance to heat and corrosion. From a
manufacturing standpoint, any of the austenitic
grades (Series 300) of stainless steels may be used;
however, from
A commercial point of view, only Type
316L is available in the wide range of particle sizes
necessary to make porous PM parts conforming to a
variety of specifications.Moreover, Type A-304 its
higher nickel and molybdenum content is more
corrosion resistant than the standard Type 302/303
stainless.
Stainless steel porous parts made from Type
316 have the same resistance to oxidation and
degradation of strength at elevated temperatures as
fully annealed Type 316L stainless. Corrosion
resistance is somewhat less than wrought stainless
because of the large amount of surface area and
relatively small inter particle bonding.
b) Making core balls
The spherical cores are made manually for
the required dia 10 to 15 mm.
Core balls made by Silica sand & bentonite
(Ratio 4:1) with sufficient amount of water
Fig 2.1 Image of core for porous casting
c) Design and fabrication of Core boxes
The design and fabrication of pattern square
die dimension 250x250x65 mm3 ,
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

The superheated molten metal was poured,

Then the steel mould was rotated manually for 1-2
minutes then it was allowed it to cool, after
solidification, the casting was taken out and water jet
cleaned to remove the cores

3. CHARACTERIZATION
a) Weight of the produced porous casting
The density of the casting was calculated by
measuring the produced casting weight after water jet
cleaning and the volume of the casting
Weight=Weight of the porous casting
% Actual Volume of casting
Fig. 2.2. Schematic representation of the Pre shaped
cores process. =11.3 Kg X 100
30 Kg
= 37 %
b) Porosity
Is a quality, which is difficult to define
precisely, because the total interconnected porosity is
not only a range of pore diameters but also the
passage of varying lengths and tortuosity.
The total open volume of interconnected and
isolated porosity is normally included in this %
porosity,
Calculated approximate percentage of
d) Production method porosity.
The spherical cores are made manually for %Porosity = (Bulk casting weight-Produced
the required diameter and arranged in the steel casting weight) x100
mould. The mould was then closed with the top plate
and preheated to 200c to remove excess moisture Bulk casting weight
content, = (30Kg- 11.3Kg) x100
30Kg
= 63.3%
c) Microstructure
All the specimens were taken into
microstructure analysis. The specimen is well
polished and Hydrochloric acid etchant is applied for
10 to 60 seconds to capture the microstructure,
microstructure has taken for 100-micron size.

Fig 2.3 Image of produced porous stainless steel

castings

The complete die was placed on the steel

frame and positioned horizontally

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 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy
Fig 3.1 Optical microstructure of porous stainless
steel casting shows dendrite phase of austenite
Fig 3.2 Optical microstructure of porous stainless
steel casting shows dendrite phase of austenite
Fig3.3 Optical microstructure of porous stainless
steel casting shows chromium carbides along the
grain boundaries in the matrix of austenite.
d) Radiography Test
The radiographic test images show no bulk
segregation of metal at any location
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4. PROPERTIES
a) Strength
The strength and moduli of porous metals
are related to the density and the properties of the
fully annealed base metal.
b) Shape
The optimum shape of a part is controlled
not only by the space available, but also by the
method of manufacture. Each manufacturing method
has its own set of advantages and disadvantages
5. APPLICATIONS
Porous metals can be used in sodium leak
collection tray, they can also be used as Fluid flow
material & pressure control, Storage reservoir for
liquids, Flame & spark arrester, Sound dampening &
Attenuation Filters.
Porous materials are regarded as the
potential candidate for crash elements, thermal
barriers, damping materials, etc.
The best suited to define this type of metals
would be multi functionality.
 Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy
6. DESIGN ADVANTAGES
a) Performance
i). High strength, corrosion resistance and durability
properties.
ii). Controlled porosity to achieve specified filtration
properties
iii). Wide range of design possibilities permitting
filtration of pore sizes,
b) Availability
i).Made from commercially available metals
ii). Manufactured in a variety of shapes and sizes.
c) Cost
i). Volume production techniques are well established
ii). Parts are usually well suited for automatic
assembly
iii). Close dimensional control is routinely achieved
d.) Industry Standards for Pore Size, Density and
Permeability
i). Mean and Maximum Pore Size- ISO 4003
ii).Bubble Point Pore Size ASTM E128-61
iii).Permeability- ISO 4022
7. RESULT AND DISCUSSION
From the above experiments it is clear that
preformed cores were found to be best method for
producing porous casting with interconnected pore
structure which is suitable for thermal transfer
application. The pore sizes from 6 mm to 25 mm
obtained using this technique. The weight of the
casting produced using the method was porosity of
60 to65%.
8. CONCLUSION
1. The casting of stainless steel foams was
successfully produced by pre-shaped cores using low
cost induction melting technique.
2. The open cell pores were preciously controlled for
stainless steel foam component and they were studied
by x-ray radiographic test.
3. The obtained pore size on the stainless steel foam
are 8 to 25 mm .The size and shape of the pores can
be controlled by the size of inorganic performs used
in the production of produced castings
4. The results of the produced porous casting
revealed no bulk segregation of metal at any place of
the castings.
9. ACKNOWLEDGEMENT
I extend my sincere thanks
DR.P.GOPALAKRISHNAN Head of Department,
Metallurgical Engineering, PSG College of
Technology, and Coimbatore to precede the project
from scratch to completion. My sincere thanks to
MR.S.VELMUTHU, Production In charge, PSG
Foundry & sons for his valuable guidance and
encouragement to successfully complete the work. I
heart fully thank T. PRABHU, Senior Research
fellow, PSG College of Technology for his help in
providing facility whenever required.
REFERENCES
1.Chastel, Y., Hudry, E., Forest, S. and Peytour, C.
(1999) In Banhart, J., Ashby, M.F. and Fleck, N.A.
(eds), Metal Foams and Foam Metal Structures,
Proc. Int. Conf. Metfoam99,
2.Wadley, H.N.G. (eds), Porous and Cellular
Materials for Structural Application, Materials
Research Society Proceedings, Vol. 521, MRS,
Warrendale, PA, USA
3.Abramowicz, W. and Wierzbicki, T. (1988) Axial
crushing of foam-filled columns. Int. J. Mech.
Other web sites of interest
1.http://www.karmann.de/d/d 2/index d 2.htm
Karmann GmbH web site describing innovative use
of metal foams in concept vehicles
2.http://www.ultramet.com/7.htm
Details of methods of making lightweight foams
3.http://www.dedienne.dedienne.com/fiches/materiau
xuk.htm Advanced materials listing
4.http://www.shelleys.demon.co.uk/fea-sep.htm
Materials magazine article highlighting metal foam
manufacturing methods
to
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