Optimization of the process parameters for the manufacturing of open-cells iron foams with high energy absorption

In this work the main results of the experimental research aimed to manufacture iron foams are reported. Iron powders (base metal) have been mixed with urea (filler agent) in different relative amounts (60% Fe- 40% urea, 50-50, 40-60 and 30-70) and then compressed in a cylindrical die in order to obtain a compact precursor. After compaction, the filler agent has been removed from each precursor in boiling water. The successive manufacturing step has been sintering and for this operation the optimum temperature has been found at 950 °C. Finally such foams have been subjected to compressive tests. Different amounts of Fe and urea match with different density and mechanical behavior in compressive tests. Energy absorbed during deformation has been calculated from the stress-strain compressive curve. Plateau stress, total strain and absorbed energy during deformation have been found strictly dependent from the iron/urea ratios.