Title:
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Mechanical and acoustic properties of porous steel manufactured by lost carbonate sintering
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Over the last few decades, porous metals have received a large amount of interest in
industry due to the rapid advancement in manufacturing techniques, design and
possible applications. Their unique properties and multi-functionality allow them to be
utilized in many different applications throughout different industrial sectors.
This thesis manufactured porous steel using the Lost Carbonate Sintering (LCS)
method and studied their mechanical and sound absorption properties. The dissolution,
decomposition and re-sintering routes were studied and compared.
The mechanical properties of the specimens manufactured by LCS via the dissolution
and decomposition routes were measured by compression and three-point bending
tests. The compression strength, elastic modulus and flexural strength of the porous
steel specimens manufactured with both routes increased with increasing relative
density, pore size and compaction pressure. Increasing the sintering temperature and
time in the decomposition route served to increase the compression strength, elastic
modulus and flexural strength. The advantages and disadvantages of the dissolution
and decomposition routes were analyzed. The porous steel specimens manufactured
by the decomposition route had better mechanical properties than those manufactured
by the dissolution route.
The acoustic absorption performance of porous steel manufactured by the LCS
process via the dissolution route was assessed using the standing wave impedance
tube method. The single layer specimens showed excellent sound absorption
properties at high frequencies. Pore size of the porous steel had no significant effect
on the sound absorption coefficient. Sound absorption at low frequencies can be
improved by increasing the thickness of specimens, or by introducing an air gap
behind the absorber.
The sound absorption properties of the porous specimens of multi-layer assemblies
with different porosities, pore sizes, thicknesses and air-gap depths were assessed. The
porosity of the first layer of multi-layer-assembled specimens had a critical effect on
the sound absorption coefficient and frequency of peak. Increasing this porosity
increased the sound absorption coefficient at all frequencies after the peak. The effects
of the porosities of the subsequent layers were smaller. When the first layer had a high
porosity, increasing the porosity of the second layer increased the frequency of peak.
When the first layer had a low porosity, increasing the porosity of the second layer
enhanced the sound absorption coefficient of peak. The effects of pore size were not
significant. Increasing the thickness of specimens and the depth of air-gap behind the
specimens decreased the frequency and coefficient of the peak in the sound absorption
curve.
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