To Produce an Advanced Zamak5 Composite with a 3D-Open Cell Copper Foam ‎by Casting Method

The aim of the present study is to produce advanced metal matrix composites in an innovative route. In fact, reinforcement phase in the advanced composite is a 3D-copper open cell foam as a continuous precursor and liquid of Zamak5 alloy is penetrated into porous space of the 3D-copper foam by casting method. Then effect of supper-heat was investigated on the liquid permeability of the molten Zamak5 and inter-diffusion at Cu/Zamak5 interface during casting in a metallic mold. Results show that by preparing open-cell copper foam with 800 micrometers thickness, 8-20 PPI, and 65 Celsius degree super-heat for Zamak5 casting alloy, production of an advanced 3D-Cu foam-Zamak5 without misrun and cold shut defects during the filling of the metallic mold can be obtained. These condition led to a complete link between 3D-copper foam and Zamak5 matrix, by interfusion mechanism at interface of Cu (3D)/Zamak5 at 450 casting temperature. Also, the 3D copper foam as an internal chill led to formation of fain dendritic structure.