ABSTRACT A new sintering method is developed for fabricating large, 3-dimensional, open-cell metal foam parts using milling or friction stir welding machines. Temperature and pressure required for sintering are achieved by plunging and moving a rotating tool against a sacrificial top sheet in the setup. Predefined tool paths are used to compress and sinter the powder mixture in a die cavity. In this paper, the method was used to fabricate open-cell copper foam plates using sintering and dissolution process (SDP). Samples with different porosities were fabricated. Produced foams have uniform mechanical properties, pore morphology, and porosity. Further, their mechanical properties are seen to be on par with that for copper foams fabricated using other sintering methods reported in literature. Except for top sheet, the setup can be reused any number of times. The developed process is robust, cost-effective, operator friendly, and easy to use.

中文翻译：

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一种用于制造开孔泡沫金属零件的烧结新方法

摘要开发了一种新的烧结方法，用于使用铣削或搅拌摩擦焊机制造大型 3 维开孔金属泡沫零件。烧结所需的温度和压力是通过将旋转工具插入并移动到设置中的牺牲顶板来实现的。预定义的工具路径用于在模腔中压缩和烧结粉末混合物。在本文中，该方法用于使用烧结和溶解工艺（SDP）制造开孔泡沫铜板。制备具有不同孔隙率的样品。生产的泡沫具有均匀的机械性能、孔隙形态和孔隙率。此外，它们的机械性能被认为与文献中报道的使用其他烧结方法制造的铜泡沫相当。除了顶板，该设置可以重复使用任意次数。所开发的工艺稳健、经济、操作友好且易于使用。