Methodology for the production of Ni-based open-cell metal foam using ultrasound-assisted electroplating

Metal foam is a new type of metal that has a variety of uses because its properties can be customised to suit a specific need. Since it has the potential to replace traditional metals, it is important to explore the most advanced methods for creating foams with various levels of porosity. However, it is difficult to produce metal foam cost effectively while also achieving the desired properties due to the random structure and complexity of the process. Therefore, this manuscript outlines a step-by-step guide for creating Ni-based foam using electrodeposition, which overcomes these developmental challenges. Also, the manuscript discusses the characterisation of the foam’s integrity parameters at each stage, as well as the problems encountered during production and their solutions to optimise the developmental process. Finally, the manuscript presents mechanical testing results that demonstrate the foam’s compressive strength of 10.21 MPa at 80% length reduction, porosity of 92% and pressure drop through foam of 0.026% was reported. The developed foam can find usability in corrosive and high-temperature filtration systems, substantiated by mechanical testing results, that are also described.