Comparison of aluminium foams prepared by different methods using X-ray tomography

The cell structure and mechanical properties of aluminium foams prepared by melt foaming (MF) method are supposed to be better than the ones produced by gas injection (GI) method. Preparation processes of these two methods have been developed during the last recent years. Mechanical properties of aluminium foams depend strongly on characteristics of the cell structure. Therefore, it is necessary to compare cell structures of the foams fabricated with these two methods quantitatively using X-ray computed tomography and this is the purpose of the present paper. MF and GI foams have thus been prepared. True density measurements and cell structures indicate that the volume fraction of the closed cells of MF foam with high porosity is negligible. By contrast, the majority of cells of GI foam are closed. Results of cell structure analysis show that there are more micropores in cell walls of the foams prepared by MF method compared to the ones prepared by GI method, especially for the MF foams with low porosity. In addition, results of cell size study show that the cell size distribution is wide in dynamic GI foams, and there are usually big holes inside MF foams. GI method is more suitable to prepare aluminium foams with high porosity compared to MF method. Furthermore, the thickness difference between normal cell wall and Plateau border is greater in GI foams, in particular for the ones produced by the static injector.