Production and testing of syntactic metal foams with graded filler volume

Abstract The purpose of innovative engineering inventions in our modern world is not necessarily to solve a new problem, but to implement and optimize an existing solution in a more energy-efficient and cost-effective manner. This can be achieved by increasing the load-bearing capacity or reducing the weight. Using these two methods simultaneously we can produce so-called syntactic metal foams. The mechanical properties of syntactic foams are highly dependent on the filler materials’ volume. Therefore, in the course of our research, we produce gradient syntactic metal foams (GSMFs) with gradient filler volume within one metal foam. Mechanical analysis as compressive tests and microstructural analysis were performed to determine the properties of the differently filled syntactic metal foams.