Open-Cell Aluminum Foams by the Sponge Replication Technique: A Starting Powder Particle Study

Abstract

Open-cell aluminum foams are manufactured by a sponge replication technique, and the effect of aluminum particles with different shapes and particle sizes on foam properties is studied. It is found that aluminum powder with spheroidal particles leads to aluminum foams with a lower strut porosity, a lower amount of alumina, and a higher compressive strength compared with foams manufactured from flaky, irregularly shaped aluminum powder. This effect is explained with the lower surface area of the first mentioned type of powder.