Investigation on the microstructure and compressive behavior of open-cell copper- Al2O3 composite foams

The objective of this study is to evaluate the mechanical behavior and energy absorption characteristics of open-cell copper- Al 2 O 3 composite foams fabricated using polyurethane foam with an average pore size of 1.2 mm and a combination of electroless and electrodeposition methods. During electroplating process, the composite foams were fabricated with varying amounts of Al 2 O 3 particles (0.1, 0.6, 0.8, and 1 g/l) in electrolyte solution. To assess mechanical properties of the fabricated foams, uniaxial compression test was conducted to determine the maximum compressive strength, energy absorption density, efficiency, and specific energy absorption. The content of Al 2 O 3 in the fabricated composite foams was evaluated using energy dispersive X-ray (EDX) analysis, and the microstructure was examined using scanning electron microscopy (SEM). The results indicate that the incorporation of Al 2 O 3 particles significantly improves the mechanical properties of the copper-Al 2 O 3 composite foam. Specifically, in the composite foam with 9.34 vol.% of Al 2 O 3 particles, the maximum compressive strength, total energy absorption, specific energy absorption, and energy absorption efficiency reach 1.03 MPa, 6.48 MJ.m -3 , 1.9 J.g -1 , and 75%, respectively. This amount of alumina particles enhances the maximum compressive strength and total energy absorption of open-cell copper foam by approximately 30% and 100%, respectively. However, the mentioned parameters slightly decreased with an increasing amount of Al 2 O 3 particles up to 16.32 vol.%. These significant improvements in the mechanical properties of these foams make them well-suited for high-strength applications.