**3.4 Experiment no. 4**

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

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

**Figure 13.** *Setup for making a foam.*

**Figure 17.**

**Figure 18.** *Metallic foam.*

**Figure 19.**

**101**

*Microstructure of metallic foam sample 4.*

*Add calcium carbonate and stir it.*

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

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

**Figure 14.** *Aluminum melted in a pit furnace.*

**Figure 15.** *Mold.*

**Figure 16.** *Aluminum poured into the mold.*

*Design and Development of Manufacturing System Design for Producing Metallic Foam DOI: http://dx.doi.org/10.5772/intechopen.92879*

**Figure 17.** *Add calcium carbonate and stir it.*

**Figure 18.** *Metallic foam.*

**Figure 15.** *Mold.*

**Figure 14.**

*Aluminum melted in a pit furnace.*

*Foams - Emerging Technologies*

**Figure 16.**

**100**

*Aluminum poured into the mold.*

**Figure 19.** *Microstructure of metallic foam sample 4.*

*vw* <sup>¼</sup> *mw ρw*

= 3.5�10�<sup>5</sup> <sup>m</sup><sup>3</sup>

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

Density of aluminum: *<sup>ρ</sup>*Al <sup>¼</sup> *<sup>m</sup>*Al

<sup>ρ</sup>Al = 2.42 � <sup>10</sup><sup>3</sup> kg/m<sup>3</sup>

**5. Density of metallic foam**

<sup>ρ</sup><sup>f</sup> = 0.4230 � 103 kg/m<sup>3</sup>

**6. Conclusion**

product.

0.4230 � <sup>10</sup><sup>3</sup> kg/m<sup>3</sup>

**Author details**

**103**

Shyam Sunder Sharma

.

provided the original work is properly cited.

.

.

Dimension of piece = 65 � 20 � 15 mm. Volume of piece = 1.9500 � <sup>10</sup>�<sup>5</sup> <sup>m</sup><sup>3</sup>

The density of pure aluminum was 2.319 � <sup>10</sup><sup>3</sup> kg/m<sup>3</sup>

Weight of metallic foam piece = 8.25 g = 0.00825 kg.

.

The volume of water was equal to the volume of the aluminum piece:

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

So, there were some impurities in the aluminum that are used in this research.

Cut a rectangular piece of metallic foam and take the weight of that piece.

.

There is a large potential for metal foam applications. However, there are several

The system was designed, fabricated and controlled for aluminum foam genera-

improvement identified, research objectives were set to design a new foam product and develop a new method of production to overcome the present shortcomings. Given the current results of this research work, it is evident that these areas for improvement have been addressed, and the knowledge gained from this work lends

Calculate the dimensions of piece also and find the volume of that piece:

deficiencies with the current technology. With these opportunities for the

valuable information to plan future actions for further improvement to this

tion. The obtained foam was tested, and the density of metallic foam was

Department of Mechanical Engineering, Manipal University Jaipur, India

\*Address all correspondence to: shyamsunder.sharma@jaipur.manipal.edu

© 2020 The Author(s). Licensee IntechOpen. This chapter is distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/ by/3.0), which permits unrestricted use, distribution, and reproduction in any medium,

.

*v*Al .

**Figure 20.** *Microstructure of metallic foam sample 4.*

aluminum was cooled down, casting can be taken out from the mold. In **Figure 19** the microstructure of metallic foam that was produced was shown.
