Effect of compaction pressure on the structure and mechanical properties of functionally graded aluminium-glass microsphere (FGAGM) foams produced by powder metallurgy process

Functionally graded aluminium-glass microsphere (FGAGM) foams were successfully fabricated via powder metallurgy. The influence of compaction pressure on the structural and mechanical properties of the foams was systematically investigated. The study observed that increasing compaction pressure enhanced the green (pre-sintering) density of FGAGM foam, while post-sintering densities exhibited a decreasing trend with higher compaction pressures. The mechanical examination indicated that mechanical properties improved significantly with higher compaction pressures. While higher compaction pressures generally improve mechanical properties, the study identified that excessive pressures could lead to the fracture of GM particles, introducing defects that compromise the foam's structural integrity. Therefore, determining an optimal compaction pressure is crucial to maximize mechanical performance while preserving the integrity of the composite constituents.