**3. Experiment**

The setup that was fabricated, with the use of this setup metallic foam, has been produced. For producing metallic foam, calcium carbonate is added into liquid aluminum and was stirred. Gases are formed at the time of stirring, and gas is entrapped into the liquid aluminum, and holes (porosity) are created into the aluminum. The foam that was formed can be cooled down, and after cooling the metallic foam can be taken out from the mold. Six experiments were done, and how much amount of aluminum and calcium carbonate can be taken is given below.

help of a wire cut electric discharge machining. The microstructure of metallic foam

*Design and Development of Manufacturing System Design for Producing Metallic Foam*

Experiment 3 was not successful because calcium carbonate was directly added into the molten metal at the time of melting. All gases were escaped, and foam was

This was the fourth experiment. In the previous experiments, some ideas are obtained, and some standardization step was taken. The amount of aluminum was 969 g and the amount of calcium carbonate was 20 g (2% of weight). The process of producing metallic foam was shown in **Figures 13**–**19**. In **Figure 13** the setup is shown, which was used for producing metallic foam. In **Figure 14** aluminum metal was melt in a pit furnace. When aluminum melted, a slag was formed due to the impurities in the metal. In **Figure 15** mold was there in which molten metal was pouring. The mold was preheated with the help of a torch of gas welding. Preheating was required to reduce the temperature difference. In the mold there was one hole in the bottom. It was taken out molten metal after the foam was produced. In **Figure 16** the molten metal was poured into the mold. 20 g of calcium carbonate is divided into three parts. One part of 6 g was drawn before the molten metal is poured into the mold. When half of molten motel was poured, 7 g of calcium carbonate was added. In **Figure 17** the molten metal was stirred and the remaining amount of calcium carbonate was added. The stirring time was 60 s. After stirring, the stirrer was taken out. In **Figure 18** foam was generated due to the formation of gases, and these gases were entrapped in the aluminum. When the

is given in **Figure 12a** and **b**.

Weight of aluminum = 665 g. Amount of CaCo3 = 30 g.

*DOI: http://dx.doi.org/10.5772/intechopen.92879*

Weight of aluminum = 969 g. Amount of CaCo3 = 20 g.

**3.3 Experiment no. 3**

not produced.

**Figure 13.**

**99**

*Setup for making a foam.*

**3.4 Experiment no. 4**
