A novel solid state method for manufacturing Al foams by over solution heat treatment

• Foams were obtained in-situ by over solution heat treatment of Al-alloys.
• The size of the pores directly increased with heat treatment temperature.
• The effect of Mg on the microstructure was analyzed.

The present study shows a new manufacturing process of foams of Al alloys by the modification of the conventional solution heat treatment of three alloys Al-6Si-3Cu-xMg (x=7, 9 and 11 wt%). Over-heating the alloys during 6 h at 520, 560 and 600 °C allowed to obtain foams with maxima porosities of 40% and pore sizes from 20 to 150 µm, originated due to the localized melting of second phases. The characteristics of the foams highly depended on the Mg content and the heat treatment temperature.

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