Fabrication of Open-cell Aluminum Foams by Pressure Infiltration and Salt Leaching Method from Commercial Grade Alloys

Abstract

This research studied the fabrication method for open-cell aluminum foams by replication process which was based on pressure infiltration and salt leaching method. Melting process was studied at temperature range of 600-750C. Four different sizes; 22, 13, 10 and 6 mm of Australian salt were used as space holders for the replication method. The experiment was carried out in a tightly closed stainless steel mold and argon gas pressure at 1.5 bar was applied during infiltration process. This research investigated suitable temperature for fabricating aluminum foams from commercially pure aluminum (99.7%Al) and ADC12 aluminum alloy (85.5%Al-10%Si-1.8%Cu). The study showed suitable temperatures for the melting process of pure aluminum foams at 725C and ADC12 at 650C. Aluminum foams fabricated in this study had interconnected strut network with % open porosity varied in the range 55-70%.