An experimental investigation was conducted in order to evaluate the edge finishing and damage effects on the transverse rupture strength (TRS) of non-graphitic carbon foam. Machining tests were conducted on Carbon Foam using an end milling process employing diamond abrasive (DA) and polycrystalline diamond (PCD) cutting tools. The surface roughness and damage induced during machining was measured using surface profilometry and scanning electron microscopy respectively. Four-point bending tests were conducted in order to determine the TRS. It was found that the damage induced during the machining of the samples had no significant effect on the transverse rupture strength of the material within the experimental conditions. The measured flexural strength was found to be 2.38 MPa and 2.25 MPa for PCD and DA machined conditions respectively. Machining induce micro-damage including micro-cracking was estimated to be 25–75μm in length. The measured average cell diameter was found to be 1120μm. The induced micro-chipping and cracking is negligibly small when compared to the cell diameter and therefore does not contribute to any stress concentration or reduction in residual strength. This research demonstrates the material’s natural geometric features which are believed to dominate the damage tolerance behavior.

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