The main aim of this research is to mathematically describe the influence of the processing parameters of metal foam production from machining chip waste. Using this method, metal foams were produced without a remelting step, which should be both economically and environmentally effective. Firstly, expensive metal powders were replaced with waste in the form of machining chips. Secondly, machining chip waste was recycled without any significant material losses, which usually occurs during conventional recycling (using the melting process). To describe the innovative process and to relate metal foam properties to foaming temperature, the blowing agent weight percentage, and foam density (controlled by foaming height), response surface methodology, and the design of experiments were used. The quality of the produced metal foams was evaluated by determination of density, yield strength, compression strength, plateau stress, energy absorption, pore perimeter, and pore inhomogeneity for specimens obtained following the experimental plan. It was proven that pore inhomogeneity increased in the range from 1.41 to 4.81 mm with a higher temperature and the addition of a foaming agent. However, higher energy absorption and yield strength were obtained with a higher temperature but a lower percentage of TiH₂. Despite the production from machining chips, pores were homogenous without significant cracks. These kinds of metal foams are comparable to commercial foams made of metal powders.

In this paper, a novel method for the double heat treatment of ductile iron was applied. Ten sets of specimens (three specimens in each set) of ductile cast iron (DCI) containing 0.51% wt. Cu were prepared and converted to austenitic ductile iron. All specimens were austenitized at 850 °C for 60 min and annealed at 420 °C, 331 °C and 250 °C for 120, 68 and 30 min, respectively. Five sets of samples were then annealed at 500 °C for 60 min, creating a novel double heat treatment process for annealing. Finally, all specimens were slowly cooled in air at ambient temperature. Tensile strength, hardness and elongation were measured in all specimens to compare the specimens with and without subsequent tempering. A microstructural analysis was also performed, which showed that the microstructure changed for the specimens that were subsequently tempered with. The results show that specimens with subsequent tempering have slightly higher hardness, a small decrease in tensile strength and significantly higher elongation. In addition, specimens with subsequent tempering exhibit more uniform mechanical properties compared to specimens without subsequent tempering. The use of neutron beam techniques was proposed to further characterize the newly formed microstructure after subsequent tempering.