Producing replicated open-cell aluminum foams by a novel method of melt squeezing procedure

In this paper, we illustrated a novel method for producing replicated open-cell aluminum foams. This was accomplished via three steps: 1) the NaCl cubic particles as space-holder material were stirred into the melt at low volume fractions, 2) excess metal was squeezed out of the composite using a filter-equipped piston which retained the solid salt into the composite and 3) the composite was solidified and the salt was leached out. The current study shows that the degree of pores opening as well as porosity percentage of foams can be enhanced by increasing the piston pressure. Through this simple technology, aluminum foams with porosities up to 65%, homogeneous structures, and acceptable compressive strength were achieved.

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► Open-cell aluminum foam was produced by the novel method of melt squeezing procedure.
► The foam microstructure and porosity is related to amount of piston's pressure.
► The compressive strength is varied by value of porosities.