Fabrication of metallic composite foam using ceramic porous spheres “Light Expanded Clay Aggregate” via casting process

• Fabrication of metallic composite foam via casting process.
• LECA was used as space holder for the produced composite metal foam.
• We test mechanical properties of composite metal foam experimentally.
• Structural characterization, relative density and compressive test were studied.
• Composite foams production has structure homogeneous and isotope properties.

Composite metal foam was produced as an advanced porous material, using gravity casting technique. Light Expanded Clay Aggregate “LECA” was used as space holder for the produced composite metal foam. The used LECA density was 0.33–0.43 g/cm3 and the volume fraction of its porosity was from 73 to 88 vol.% and aluminum A355.0 was selected as matrix in order to produce the composite foam. Structural characterization, relative density, hardness and compressive test were studied. The composite metal foam was well investigated and found to have homogeneous structure, relatively equal pore, distributable pore and isotropy properties. The study resulted in that relative density, yield strength and energy absorption capacity were 0.44, 35.9 MPa and 18 MJ/m3, respectively.