Manufacturing of Open-Cell Metal Foams Using a Novel Leachable Pattern

A space-holder method using crystalline carbohydrate particles, as a novel leachable pattern for manufacturing open-cell metal foams is described. The method involves mixing and compaction, leaching and sintering processes. Open-cell Al foams with porosity up to 70% can be produced. The removal of the carbohydrate particles from the green compact is achieved by water leaching at room temperature. An appropriate sintering leads to a very good result as far as the microstructure achieved is concerned.