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Fabrication and Mechanical Properties of Open‐Cell Austenitic Stainless Steel Foam by Electrostatic Powder Spraying Process

An open‐cell metallic foam is newly manufactured using the electrostatic powder spraying (EPS) process, and its room temperature compressive and energy absorption properties are investigated. EPS is a process that uses electrostatic forces. The powder is negatively charged by applying direct current high voltage and undergoes electrostatic spraying on a positively charged polyurethane pre‐form. To control relative density (ρ*/ρ), three different spray amounts are applied (2.5, 3.5, and 4.5 kg m−2). Also, the relative density is measured to increase constantly with the spray amount. The room temperature compressive curves of the EPS foams represent the typical compressive stages (linear elastic, plastic collapse, and densification) of metallic foam. The plateau strengths of the EPS foams measure 0.48 MPa (spraying amount: 2.5 kg m−2), 0.76 MPa (spraying amount: 3.5 kg m−2), and 1.23 MPa (spraying amount: 4.5 kg m−2), respectively. Also, EPS 316L foam with the smallest spray amount has a lower energy absorption amount compared with other types of foam. This study also discusses the compressive and energy absorption behaviors of an open‐cell metallic foam manufactured using the EPS process in relation to its structural and microstructural characteristics.