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Open-cell Al-4.5Cu (wt.%) foams were produced by the replication casting technique in cell sizes of 2.00-2.38 and 3.35-4.75 mm. The fabricated foams were subjected to solution and aging treatments to assess the effect of such heat treatments on the microstructure and mechanical properties of the foams as a function of cell size. Solution and aging heat treatments were carried out at 535 °C for 5.5 h and 170 °C for 8 h, respectively. The porosity and relative density of all produced samples were estimated by He pycnometer. In addition, the average cell wall thickness was assessed by image analysis to correlate this variable with the response to heat treatments of the material. The microstructural evolution of the heat-treated samples was analyzed by means of scanning electron microscopy, scanning transmission electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and differential scanning calorimetry. The mechanical characterization of the studied samples was carried out using uniaxial compression tests and microhardness tests. It was found that the foams did present different responses to both solution and aging treatments as a function of cell size, attributing these outcomes to the cell wall thickness variations, which presumably conditioned the cooling rates after heat treatments, thereby influencing the resulting microstructures and precipitation of Al-Cu second phases.

Open-cell Al-4.5Cu (wt.%) foams were produced by the replication casting technique in cell sizes of 2.00–2.38 and 3.35–4.75 mm. The fabricated foams were subjected to solution and aging treatments to assess the effect of such heat treatments on the microstructure and mechanical properties of the foams as a function of cell size. Solution and aging heat treatments were carried out at 535 °C for 5.5 h and 170 °C for 8 h, respectively. The porosity and relative density of all produced samples were estimated by He pycnometer. In addition, the average cell wall thickness was assessed by image analysis to correlate this variable with the response to heat treatments of the material. The microstructural evolution of the heat-treated samples was analyzed by means of scanning electron microscopy, scanning transmission electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and differential scanning calorimetry. The mechanical characterization of the studied samples was carried out using uniaxial compression tests and microhardness tests. It was found that the foams did present different responses to both solution and aging treatments as a function of cell size, attributing these outcomes to the cell wall thickness variations, which presumably conditioned the cooling rates after heat treatments, thereby influencing the resulting microstructures and precipitation of Al-Cu second phases. Graphical abstract

Open-cell Al foams were produced by the replication casting technique in three different pore sizes. All produced foams were physically characterized, determining their relative density, porosity, and pores per inch, as well as their mean pore surface area and diameter. Permeability tests were carried out by means of the injection of a highly pressurized gasoline additive at room temperature and 200 °C, at pressures of up to 25,000 psi. The structural capacity of the studied specimens to conduct fluids at these critical experimental conditions was assessed by means of compression tests in order to determine their mechanical properties after the permeability tests, e.g., energy absorption capacity, Young’s modulus, and plateau stress. It was found that the produced open-cell Al foams were able of conducting the gasoline additive at critical flow conditions of pressure and temperature, without suffering important physical nor structural damage. Graphic abstract

This study investigates demineralized bone matrix (DBM) combined with magnesium (Mg) to create degradable composite materials. Two types of DBM were utilized: carbon-coated (H.A.) and non-carbon-coated (HA-HT). An advanced liquid metal infiltration method prevented the structural collapse of the scaffold due to capillary forces. Both composites exhibited an interphase layer primarily composed of MgO, differing in thickness by 50%, attributed to the reaction between H.A. and Mg. The Mg/H.A. composite demonstrated a compressive yield strength 1.7 times higher than Mg/HA-HT, resembling Mg’s mechanical behavior but with a lower metal phase fraction than other composites. Compared to pure Mg, the composites generated less hydrogen (45–54 ml cm −2 ), reducing the corrosion rate (~ 0.1181 mm year −1 ) under simulated conditions (90 ml cm −2 and 4.2 mm year −1 for Mg). A localized phenomenon was identified mainly at the interphase of both composites but specifically in the Mg/H.A., where the scaffold structure was kept over extended exposure periods. These materials hold promise for temporary bone fixation applications. Graphical abstract

Aluminum (Al) and Al–4.5Cu wt% open-cell foams were produced by the replication casting technique in two different pore sizes, avoiding subsequent heat treatments. All produced samples were physically characterized by means of He pycnometry. Microstructural and chemical analyses were carried out using scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray diffraction and image processing techniques. Uniaxial compression tests were conducted, with the aim of generate the stress–strain curves of the Al and Al–4.5Cu wt% foams. It was found that plastic collapse and plateau stresses increased from ~ 3 and ~ 12 MPa to ~ 10 and ~ 30 MPa, while the energy absorption capacity of the Al–4.5Cu wt% foams was almost trebled regard the pure Al foams. These outcomes were attributed to the formed microstructure, constituted by dendritic arrangement of α -Al (~ 57 HV) and θ -Al 2 Cu (~ 326 HV). Thus, this work gives way to produce mechanically enhanced open-cell Al foams derived from the Cu addition. Graphic abstract