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<p>The nickel foam metal owns a high melting point and a unique pore structure, which causes difficulty in welding. It is an urgent problem to solve in the application of nickel foam. Based on a single-factor experimental method, the influences of plate densification and welding speed were studied during friction stir processing (FSP) with copper powder additive. The microstructure evolution and corrosion resistance were analyzed. It was found that the welding effect is best when the densification reaches 82%, the welding speed is 100&#xa0;mm/min. The processing depth of the stirring zone is 300&#xa0;μm and the tensile strength reaches 227&#xa0;MPa. The mechanism of the copper powder additive in FSP of nickel foam found that the copper and nickel elements are distributed diffusively in the penetration area of the joint surface and copper-nickel alloy is detected. It was indicated that the surface copper-nickel metal will undergo a solid solution reaction under high-temperature and high-pressure welding. The addition of copper powder will help to improve the weldability and corrosion resistance of nickel foam. This research is significant for efficient welding and application of nickel foam.</p>

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Microstructure and Properties of Nickel Foam Sheet by Friction Stir Processing

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Gao Hui,
  • Chu Xingrong,
  • Yang Fan,
  • Zhao Zhiyong,
  • Xue Lian,
  • Zhu Xinde,
  • Lin Shuxia

摘要

The nickel foam metal owns a high melting point and a unique pore structure, which causes difficulty in welding. It is an urgent problem to solve in the application of nickel foam. Based on a single-factor experimental method, the influences of plate densification and welding speed were studied during friction stir processing (FSP) with copper powder additive. The microstructure evolution and corrosion resistance were analyzed. It was found that the welding effect is best when the densification reaches 82%, the welding speed is 100 mm/min. The processing depth of the stirring zone is 300 μm and the tensile strength reaches 227 MPa. The mechanism of the copper powder additive in FSP of nickel foam found that the copper and nickel elements are distributed diffusively in the penetration area of the joint surface and copper-nickel alloy is detected. It was indicated that the surface copper-nickel metal will undergo a solid solution reaction under high-temperature and high-pressure welding. The addition of copper powder will help to improve the weldability and corrosion resistance of nickel foam. This research is significant for efficient welding and application of nickel foam.