Closed-cell Al alloy composite foams: Production and characterization

Foamy Al alloy SiCp composites of different densities ranging from 0.4 to 0.7 g/cm3 were manufactured by melt-foaming process, which consisted of direct CaCO3 addition into the molten A356 aluminum bath. Mechanical properties and morphological observations indicated that the three-stage deformation mechanism of typical cellular foams is dominant in the produced A356 aluminum foams. Middle-stage stress plateau shrinkage plus compressive strength and bending stress enhancements were observed in denser foams. With the same Al/SiCp ratio, energy absorption ability and plastic collapse strength of the closed-cell foams were increased with the foam density. Doubling cell-face bending effects resulted in larger compressive than bending strengths in the closed-cell foams; while stiffness lowering was due to the cell-face stretching conditions.

► Foamy Al–SiCp was manufactured by direct addition of CaCO3 into the molten Al alloy.
► Compressive and bending strengths of the foams increased with their density.
► Energy absorption ability of closed-cell foams improved with their density.
► Plastic collapse strength of the closed-cell foams were improved with their density.