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<p>In this study, NaCl was used as a space-holder to produce a Ti6Al4V alloy foam with various porosities (40%–80%) through spark plasma sintering and tube furnace sintering. The microstructure of the manufactured foam exhibited a mixed structure consisting of α and β phases, and micro-CT analysis revealed that, under all conditions, the pore size was in the range of 230–280&#xa0;μm. In addition, it was observed that as the pore size increased, the neck thickness between the particles forming the cell wall decreased. Compression test results showed a three-step behavior, including the linear elastic stage, the plateau stage, and the densification stage. As porosity increased, both the compressive strength and the elastic modulus decreased due to the reduction in cell wall and neck thickness. The neck thickness between the particles forming the cell wall is associated with the relative density. With increasing porosity, the number of particles forming the cell wall decreases, and the particle–particle area where the neck between particles is formed and the compressive force between particles decreases, which is unfavorable for neck growth. Based on the observed data, a high correlation between the neck thickness and compressive strength was also derived, suggesting that neck thickness plays an important role in withstanding compressive stress.</p> Graphical Abstract <p></p>

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Correlation of Porosity, Neck Thickness, and Mechanical Properties in Ti6Al4V Alloy Foams Fabricated by the Space Holder Method

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Sungjin Kim,
  • Seunghyeok Choi,
  • Tae-Young Ahn,
  • Yu-Song Choi,
  • Jae-Gil Jung,
  • Seung Bae Son,
  • Seok-Jae Lee

摘要

In this study, NaCl was used as a space-holder to produce a Ti6Al4V alloy foam with various porosities (40%–80%) through spark plasma sintering and tube furnace sintering. The microstructure of the manufactured foam exhibited a mixed structure consisting of α and β phases, and micro-CT analysis revealed that, under all conditions, the pore size was in the range of 230–280 μm. In addition, it was observed that as the pore size increased, the neck thickness between the particles forming the cell wall decreased. Compression test results showed a three-step behavior, including the linear elastic stage, the plateau stage, and the densification stage. As porosity increased, both the compressive strength and the elastic modulus decreased due to the reduction in cell wall and neck thickness. The neck thickness between the particles forming the cell wall is associated with the relative density. With increasing porosity, the number of particles forming the cell wall decreases, and the particle–particle area where the neck between particles is formed and the compressive force between particles decreases, which is unfavorable for neck growth. Based on the observed data, a high correlation between the neck thickness and compressive strength was also derived, suggesting that neck thickness plays an important role in withstanding compressive stress.

Graphical Abstract