1

TITLE : DEVELOPMENT OF SS316L FOAM BY

USING SPONGE REPLICATION METHOD
PSM 2
Name : Adam Malik Bin Masu@Mansor
Matrix : DD130087
Supervisor : Puan Fazimah Binti Mat Noor
Panel : Prof. Madya Dr. Mohd Halim Irwan Bin Ibrahim
: Encik Rosli Bin Asmawi
 2
BACKGROUND OF STUDY
Metal foam are also known as porous metallic product.

Biomedical application especially in dental implant and

orthopaedic.

It more extremely attractive is high specific area and low density.

The high porosity of metal foam also makes metal foams very
lightweight.

SS316L is an excellent fabrication properties, lower cost, good

corrosion resistance and easy availability.
 3
PROBLEM STATEMENT

Metal foams are very important to support biological fixation of

implants.

The major problem is the mismatch of the properties between bones

and metallic materials.

There are factors that need to be considered:

The shape and the density of implants must be same with the shape and
density of bones.

The pores must be interconnecting with suitability of bones.

The pores of the implants must be same with the pores of bones.
 4
OBJECTIVES

There are two main objectives of this project which are:

a) To identify the effect of SS316L composition to the physical

properties and microstructure of SS316L foam.

b) To identify the effect of milling time on the slurry viscosity and

temperature.
 5
SCOPES OF PROJECT

To achieve the objective state, there area several ways to do it.

Prepare the SS316L slurry by using ball milling method.

The SS316L composition for the slurry preparation is fixed at 55wt%, 60 wt%, 65wt%,
70wt% and 75wt% of SS316L powder.

The milling time is fixed at 30 minutes, 60 minutes, and 90 minutes

The sintering process will be carried out at temperature of 1200C.

Using Olympus Stereomicroscope, X-Ray Diffraction (XRD) and Density and Porosity
Test.
METHODOLOGY 13

FLOWCHART
Sintering Profile

Duration in firing process is 26 hours

Firing rate is 1C/min
Temperature cooling down at
5C/min
 RESULTS AND DISCUSSION
1. Effect of milling time on the slurry temperature

Weight percentage, Time of milling, minutes Temperature, C

wt. %

55 60 29.0
60 30 27.1
60 28.0
90 27.8
65 30 27.1
60 28.2
90 27.8
70 30 27.1
60 28.9
90 27.8

75 60 28.0
 29.5

29 The slurry temperature for each

composition of SS316L foams is
`Temperature, C

28.5
not much different.
55 wt.%
28
60 wt.% There is no significant increase or
27.5 65 wt.% decrease of the slurry
70 wt.% temperature as the milling time
27
75 wt.%
increased from 30 minutes to 90
26.5
minutes.
26
30 60 90

`Time of milling, minutes

2. Effects of milling time and SS316L composition on the slurry viscosity

Weight percentage, Time of milling, minutes Viscosity , mPa.s

wt. %

55 60 106.67

60 30 191.28
60 169.76

90 178.17
65 30 437.44
60 379.67
90 410.96

70 30 977.12
60 978.06
90 990.26
75 60 6096.41
 1200

1000
Viscosity (mPa.s)

800

600 60wt. %
65wt. % That the slurry viscosity is not
400 70wt. % affected by the milling time of 30
minutes, 60 minutes and 90 minutes.
200
Since the increase of the milling
0 time from 30 minutes to 90 minutes,
30 60 90
this parameter did not much
`Time of milling (min)
contribute to the increasing of the
slurry temperature as well as slurry
viscosity.
 6300

5400
Viscosity (mPa.s)

4500

3600

2700 The graph of slurry viscosity against

1800 composition of SS316L shows the

900 increase significant of viscosity on

composition of SS316L.
0
55 60 65 70 75 The slurry viscosity is mostly affected
Composition (wt.%) by the SS316L composition than
milling time.
3. Shrinkage of SS316L foam samples

Weight percentage, Average shrinkage , %

wt. %

60 25.30
30
65 18.77
25.30
70 14.27 25

Shrinkage (%)
20 18.77
75 7.13
14.27
15

The shrinkage of SS316L foam was 10

7.13
decreased if the composition of SS316L 5
increased.
0
60 65 70 75
Composition (wt.
Composition (wt.%)
%
(a) (b) (c)

55wt.% 60wt.% 65wt.%

(d) (e)

70wt.% 75wt.%
4. X-ray Diffraction (XRD) Analysis

9000 (Fe0.6Cr0.4)2O3

(NiCr2O4)
8000
(Fe2O3)

(Fe0.64Ni0.36)
7000
(FeCr0.29Ni0.16C0.06)
6000
After sinter, 70 wt.% The presence elements of iron (Fe),
Lin (counts)

5000 nickel (Ni), chromium (Cr) and

4000
After sinter, 65 wt.%
carbon (C), has been proved that

After sinter, 60 wt.%

the element is a standard element
3000
from the SS316L raw.
2000
Before sinter, SS316L raw

1000

0
20 40 60 80
2-Theta Scale
 5. Microstructure analysis of SS316L foams
(a) (b)

Closed pore Open pore

60wt.% 65wt.%

Strut (c) (d)

Mad Rosip, (2013) reported

that the composition of
SS316L increased, the pore
shape becomes more
rounded
70wt.% 75wt.%
 Weight percentage, Average pore size ,
wt. %

60 0.7078

65 0.7878

70 0.7004

75 0.2689

0.9

The increased of composition the SS316L

0.8
0.7
induce the average of pore size was increased

Average pore size (

0.6

first and then decreased. 0.5

0.4
0.3
0.2
0.1
0
60 65 70 75
Composition (wt.%)
6. Density and porosity Test 8

Average of density (g/cm3)

6
Weight Average of Average of
percentage, density, g/cm3 porosity, %
4
wt. %

2
60 4.2506 46.19

65 4.7910 39.35 0
60 65 70 75
70 4.8710 38.34 Composition (wt.%)
50
75 4.8834 38.18
40

Average of porosity (%)

30
Rosip (2013) reported that the closed pore
foam has higher value of density due to the 20

weight is higher. 10

The decrease of porosity on SS316L foam is

0

occurred by closed pore.

60 65 70 75
Composition (wt.%)
 CONCLUSION AND RECOMMENDATION
CONCLUSIONS

It can be conclude that the results and data analysis that obtained has been successful based
on the research objectives. The SS316L foam was successfully produced by using slurry method.
It was found that there is no significant increased or decreased of slurry temperature
The slurry viscosity is not affected by milling time but it was affected by composition of SS316L
slurry.
Average of pore size of SS316L foam have achieved where the pore size was increased with low
slurry viscosity of SS316L.
Density of SS316L foam for composition of 60, 65, 70, and 75 of weight percent (wt. %) was
increased consistently with the value from 4.2506 g/cm3 to 4.8834 g/cm3.
RECOMMENDATION

The PU foam has extra time to soak in slurry and squeeze.

The microstructure observation has to be done by using Scanning Electron Microscopy (SEM).
The sintering process was done in vacuum furnace.
 14
GANTT CHART PSM 1

Week
Activities
W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

Plan
Deciding PSM title with Supervisor
Actual
Plan
Discussion of PSM title
Actual
Plan
Project proposal approval
Actual
PSM 1 report
i) Introduction
Plan
ii) Literature review
iii) Methodology

Actual

Plan
PSM 1 report submission to Supervisor
Actual
Plan
PSM 1 report submission to Panel
Actual
Plan
Improve the log book writing and submit to Supervisor
Actual
 15
GANTT CHART PSM 2

Week
Activities
W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

Plan
Briefing about PSM2 with supervisor
Actual
Development of SS316L foam by using foam replication Plan
method Actual
Plan
Data analysis and discussion, conclusion
Actual

Send draft final report and seminar paper Plan

Actual
Plan
Improve the writing of log book and final report PSM2
Actual
Plan
Send log book and draft report PSM2 to supervisor
Actual
Plan
Send final report PSM2 to faculty
Actual
T H A N K
Y O U