Replication casting of open-cell AlSi7Mg0.3 foams

A typical aluminum alloy for casting (AlSi7Mg0.3) was used to produce open-cell foams by replication of a salt precursor. The process was set to minimize complexity and costs of the casting operations: the preform sintering was avoided and mold temperature lower than the eutectic temperature of the alloy was used. Open-cell foams with a relative density about 35% and high compressive strength resulted. Material analyses showed that, in replication casting, the material response to the process is optimal and a homogeneous and fine grain size distribution is visible in the foams.