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Casting Protocols for the Production of Open Cell Aluminum Foams by the Replication Technique and the Effect on Porosity

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On the Creation and Optical Microstructure Characterisation of Additively Manufactured Foam Structures (AMF).

Anselm Heuer¹, Maike Rees¹, Kay A Weidenmann²

¹Institute for Applied Materials-Materials Science and Engineering (IAM-WK), Karlsruhe Institute of Technology (KIT), Kaiserstrasse 12, 76131 Karlsruhe, Germany.

|September 9, 2023

Summary

Optical characterization of additively manufactured foam structures is crucial for process control. This study reveals that pore shape changes with orientation, not foaming behavior, and total porosity is fixed during slicing, necessitating analysis of pore networks for accurate foaming assessment.

Keywords:

Arburg plastic freeforming (APF)chemical blowing agent degree of foaming entropy by Haralick fineness foam pores porosity process-related pores

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Process of Making Three-dimensional Microstructures using Vaporization of a Sacrificial Component

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Published on: November 2, 2013

Area of Science:

Materials Science
Additive Manufacturing
Polymer Science

Background:

Plastic-based additive manufacturing is gaining traction for structural parts.
Additively manufactured foam structures offer lightweight design and extended functionality.
Optical characterization is vital for process adjustment and identifying structural changes in foams.

Purpose of the Study:

To develop sophisticated methods for optical characterization of additively manufactured foam structures.
To evaluate porosity, pore size, pore amount, and textural changes in foam structures.
To understand how orientation and process parameters affect foam structure characteristics.

Main Methods:

Microscope image analysis of manufactured and artificial additively manufactured foam structures.
Determination of porosity, pore size, pore amount, and textural change.
Evaluation of pore shape variations based on cutting plane orientation.

Main Results:

Additive structures exhibit changing pore shapes depending on cutting plane orientation, despite consistent foaming behavior.
Total porosity is determined during the slicing process and remains constant.
Degree of foaming cannot be inferred from total porosity but can be assessed via pore network formation.

Conclusions:

Caution is needed when interpreting changes in foam structures due to orientation-dependent pore shape variations.
The slicing process dictates total porosity in additive manufacturing.
Assessing the formation of large, process-related pore networks is key to determining the degree of foaming.