Fabrication of Metal Matrix Syntactic Foams by a Laser Additive Manufacturing Process


In this study, laser additive manufacturing was applied to the fabrication of metal matrix syntactic foams. This was done with the intent of utilizing the fast cooling rates and limited kinetic energy input of additive manufacturing to reduce two issues commonly associated with the process of syntactic foams: microsphere flotation in the melt and microsphere fracture during processing. Challenges to this process include microsphere segregation during powder mixing and processing which decreases homogeneity and during the layer-by- layer microstructure of this additive manufacturing process which hinders some mechanical properties. A Fe-based and an Al-based metal matrix with glass microspheres were characterized in this study. Characterization methods included Vickers hardness and microstructural analysis.

Meeting Name

Materials Science and Technology Conference and Exhibition 2016 (2016: Oct. 23-27, Salt Lake City, UT)


Materials Science and Engineering

Second Department

Mechanical and Aerospace Engineering

Research Center/Lab(s)

Intelligent Systems Center

Keywords and Phrases

Characterization; Flotation; Foams; Kinetic Energy; Kinetics; Manufacture; Metals; Microspheres; Powder Metallurgy; Powder Metals; Syntactics; Vickers Hardness; Additive Manufacturing Process; Characterization Methods; Glass Microspheres; Laser Additive Manufacturing; Metal Matrix Syntactic Foams; Microsphere Fractures; Microstructural Analysis; Syntactic Foams; 3D Printers; Additive Manufacturing; Powder Metallurgy

International Standard Book Number (ISBN)


Document Type

Article - Conference proceedings

Document Version


File Type





© 2016 Association for Iron & Steel Technology (AIST), All rights reserved.

Publication Date

01 Oct 2016

This document is currently not available here.