In this study, porous and dense layers of alloy 625 are deposited on nickel foam sheets using a modified twin wire arc spraying process. Sandwich panels with arc-sprayed alloy 625 skins on nickel foam cores were fabricated then subjected to four-point bend testing. The effects of skin porosity on flexural rigidity and overall mechanical behavior are investigated. The ductility of porous alloy 625 skins was improved after heat treatment at 1100 °C for 3 h.

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