Solid mold investment casting - A replication process for open-cell foam metal production

Foam metals have always been an interesting material type because of their unique properties and various production techniques. In this study, solid mold investment casting process, which is one of the replication techniques, was used to produce open-cell aluminum foam specimens. Commercial rubber sponge was tested as foam pattern material. Plaster bonded solid molds were prepared in the stainless steel flasks and infiltration of the slurry into the rubber sponge was carried out under vacuum. Following this, pattern removal and mold firing was carried out gradually. Molten A319 casting and A6063 wrought aluminum alloys were cast into flash molds with vacuum assistance (-10(5) Pa). Sponge pattern and cast foam specimens were examined and compared by stereo microscope and scanning electron microscope (SEM). It is clearly found that rubber sponge is a very suitable pattern material for producing open-cell foam structures.