Application of Potassium Carbonate as Space Holder for Metal Injection Molding Process of Open Pore Copper Foam

Copper foam has recently being applied to replace aluminium as heat sink. In this study, copper foam was manufactured via metal injection molding technique. Copper feedstock were prepared comprising 0 wt.%, 30 wt.% and 40 wt.% of potassium carbonate into copper powder to produce open pore cell structure, which also mixed together with a binder system consisting palm stearin (PS), polyethylene (PE) and stearic acid (SA). The feedstock was then injection molded into tensile shape test piece prior to solvent extracted in heptane prior to sintering using tube furnace at 850oC for 4 hours in nitrogen atmosphere. The sintered samples were immersed in warm water to dissolve the carbonates. Copper foam has successfully manufactured at 850oC for 4 hours in nitrogen atmosphere followed by the dissolution process. The porosity value increased as the addition of potassium carbonate increased from 0 to 40 wt.% which given the highest value of 52.985% porosity and thermal conductivity of 520.46 W/m.K.