Performance Assessment on the Manufacturing of Zn-22Al-2Cu Alloy Foams Using Barite by Melt Route

A barium-rich Celestine (Sr,Ba)SO4 concentrate from the primary Mexican ore production was used as a thickening agent to produce closed-cell Zn-22Al-2Cu alloy foams, while calcium carbonate was used as a foaming agent. The microstructure and mechanical properties of the foams were analyzed by optical microscopy, scanning electron microscopy, and compression tests, respectively. The Zn-22Al-2Cu alloy foams showed a typical lamellar eutectic microstructure, constituted by a zinc-rich phase (η) and a (α) solid solution that was richer in aluminum, while a copper-rich (ε) phase was formed in the interdendritic regions. The SEM micrographs show the presence of small particles and aggregates that are randomly scattered in the cell walls and correspond to unreacted calcite and Celestine–Barian particles, especially for the higher barite addition. The compressive curves showed smooth behavior, wherein the particles at the cell walls did not affect the foam’s compressive behavior. The trial containing 1.5 wt. % of BaSO4 and 1.0 wt. % of CaCO3 showed a higher energy absorption capacity of 5.64 MJ m−3 because of its highest relative density and lowest porosity values. The Celestine–Barian concentrate could be used as a foaming agent for high melt-point metals or alloys based on the TGA results.