The structural and mechanical properties of open-cell aluminum foams: Dependency on porosity, pore size, and ceramic particle addition

Aluminum foams are desired for lightweight, high-performance, and cost-effective materials, particularly in automotive, aerospace, and advanced power plants. Expansion of their applications depends on developing a detailed understanding of the structural and mechanical properties of aluminum foams. In this research, open-cell aluminum foams with 25.51–81.88 % porosity were manufactured through powder metallurgy using a space holder technique, with varying carbamide (urea) ratios (17–80 %) and particle sizes (1–1.4 mm, 1.7–2 mm, 2–2.4 mm). Three different ceramic particles, B4C, Al2O3, and SiC were used as reinforcement to improve the compression properties and energy absorption capacity of the foam materials. The study determined open and closed porosity ratios, spherical diameter, sphericity values, micropore sizes, mechanical properties, and energy absorption capacity of the foam samples both with and without ceramic additives. The results show that porosity ratio, pore size, and ceramic particle addition significantly affect aluminum foams' structural and mechanical properties, allowing for tailored properties for specific applications. It was observed that as porosity increased, compressive stress decreased, and the length of the plateau region and the shape change where densification began increased. However, there was no significant change in compressive stress and specific energy values with changing pore size. The optimal B4C addition was found to be 4 %, which significantly improved compressive strength to 3.75 MPa and specific energy to 4.24 MJ m−3. •4 % B4C addition maximized the compressive strength and energy absorption capacity of aluminum foams.•Increased porosity led to a decrease in maximum compressive stress but an increase in plateau length and energy absorption.•1.7–2 mm pore size provided the highest efficiency in energy absorption capacity.•Presence of micropores significantly affected the mechanical properties of foams, especially at high porosity levels.•Ceramic particle addition improved the strength of aluminum foams without negatively impacting pore formation.