| This thesis investigates, for the first time, the production of an aluminum-carbon nanotube (Al-CNT) open-cell foam. Al-CNT (2wt.% CNT) and aluminum open-cell foams were successfully formed by a Spark Plasma Sintering and Dissolution Process (SPSDP). Al-CNT foams with porosity of approximately 78% were produced under varying sintering conditions and temperatures ranging from 350 ºC to 400ºC.;The samples underwent extensive imaging and x-ray diffraction analysis to characterize and explain the variances in structure between as-produced Al and Al-CNT foams sintered at various temperatures. Grain size analysis revealed an increase in grain size of both Al and Al-CNT foam as sintering temperature is increased. However, CNTs that are present at Al grain boundaries proved to resist grain growth, by pinning effect, when compared to unreinforced foams.;Although the focus of this thesis was the processing and characterization of CNT reinforced metallic foams, some mechanical characterization was also attempted. The mechanical response was obtained by indentation tests on Al and Al-CNT samples formed under various sintering conditions. The results show that CNT content helps to stabilize local cell wall collapse (possibly by crack face bridging) and enhance damage tolerance over unreinforced aluminum foams produced in this study. Moreover, an increase in sintering temperature resulted in a general decline in load carrying capacity of the foams. |
