Functional aluminium matrix syntactic foams filled with lightweight expanded clay aggregate particles

Abstract Is it possible to create low-cost functional composite metal foams? In the framework of this study, composite metal foams filled tubes were produced with lightweight expanded clay aggregate particles. Specimens were manufactured by low pressure infiltration in aluminium tubes with the wall thickness of 5 mm. The properties of the transition layer between the matrix material and the material of the tube were analysed with energy dispersive X-ray spectrometry. The importance of the research was to develop lightweight, high-capacity functional composite metal foams which have higher specific mechanical properties than ’conventional‘ metal foams, thereby achieving additional weight reduction and lower material requirements, primarily as moving machine parts or automotive components, while keeping overall costs low.