Experimental modelling of powder metallurgical processed copper foams using acrawax as a space holder material

Copper foams have various uses in applications such as electrode for fuel cells and batteries, filters for water purification, thermal conductivity enhancer for phase change materials, etc. This study shows the process of processing copper foams with an average pore size of 200-300 μm with 40 and 70 volume % porosity through a powder metallurgy route. Space holder technique has been employed to process the copper foams. A lubricant space holder material acrawax has been used which possesses superior properties compared to all the previously used space holders. Copper foam's physical and mechanical properties have been studied with the change in compaction pressure. Simple mathematical models have also been developed in this work using 2N factorial method. The models can be used to get the values of pore size and porosity present in the foams according to the changing parameters like amount of space holder, compaction pressure, sintering time and temperature.