Study on improvement of aluminum foams by rapid foaming

Abstract The present study shows a new manufacturing process for improving the quality of Al alloy foams by powder metallurgy method. Foaming process was accelerated by combining the actions of the modification of Al-1%Mg-xSn (x=0, 3 and 5 wt%)/7%SiC precursor and the application of foaming mould providing high heating rate. The liquid Sn filled up the voids in the precursor and helped to capture the liberated H 2 during foaming. The early expansion stage occurred in advance with addition of Sn. Foaming behaviors and the morphologies of the Al foams revealed that the stability and the final cellular structure were improved significantly.