Development of Iron-based Closed-Cell Foams by Powder Forging and Rolling

In the present investigation, an attempt has been made to develop in situ sandwich Fe-based foams using powder forging and rolling. Several metal carbonates are first studied by thermo gravimetric analysis to find out their suitability to be used as foaming agent for iron-based foams. Barium carbonate is found to be the most promising foaming agent among other suitable options studied such as SrCO₃, CaCO₃, MgCO₃, etc. The effects of process parameters such as precursor composition, sintering temperature, foaming temperature and time, and content of foaming agent have been studied. The microstructural characteristics of the sintered precursor have been studied by means of optical and scanning electron microscopy. It was found that a good pore structure can be obtained using 2-3% C in Fe and 3% BaCO₃ as foaming agent and by foaming at around 1350 °C for 3-6 min.