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<p>Increasing demands for sustainable manufacturing are accelerating the need for efficient scrap reutilization routes that extend beyond conventional remelting practices. In this context, solid-state reuse of machining chips presents a viable pathway for producing high-value functional materials while supporting circular economy objectives aligned with UN SDG-12. This work reports a novel processing strategy for fabricating stainless steel 316 metallic foams directly from turning chips using microwave sintering. Consolidation was carried out at 1050&#xa0;°C and 1200&#xa0;°C under an argon atmosphere to suppress oxidation and contamination while enabling rapid and energy-efficient sintering. Three foam architectures: chip-based, hybrid and space-holder foams, were successfully produced and systematically characterized with respect to macrostructure, microstructure and compressive response. Foams sintered at 1200&#xa0;°C exhibited a well-defined and stable stress plateau with enhanced energy absorption capacity. Their lower plateau stress facilitated progressive deformation under compressive loading, indicative of improved impact resistance. The results demonstrate that chip-derived stainless steel foams produced via microwave sintering offer strong potential for energy-absorbing and crash-relevant structural applications, while providing a sustainable route for high-value metal scrap reutilization.</p>

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Microwave sintered SS316 porous foams from machining waste and their structure and energy absorption properties

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月23日

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  • Sanket Shinde,
  • Siddharama Adi,
  • Padmakumar A. Bajakke,
  • Vinayak R. Malik

摘要

Increasing demands for sustainable manufacturing are accelerating the need for efficient scrap reutilization routes that extend beyond conventional remelting practices. In this context, solid-state reuse of machining chips presents a viable pathway for producing high-value functional materials while supporting circular economy objectives aligned with UN SDG-12. This work reports a novel processing strategy for fabricating stainless steel 316 metallic foams directly from turning chips using microwave sintering. Consolidation was carried out at 1050 °C and 1200 °C under an argon atmosphere to suppress oxidation and contamination while enabling rapid and energy-efficient sintering. Three foam architectures: chip-based, hybrid and space-holder foams, were successfully produced and systematically characterized with respect to macrostructure, microstructure and compressive response. Foams sintered at 1200 °C exhibited a well-defined and stable stress plateau with enhanced energy absorption capacity. Their lower plateau stress facilitated progressive deformation under compressive loading, indicative of improved impact resistance. The results demonstrate that chip-derived stainless steel foams produced via microwave sintering offer strong potential for energy-absorbing and crash-relevant structural applications, while providing a sustainable route for high-value metal scrap reutilization.