Method for producing foamed aluminum products

The present invention is directed to a method for making porous aluminum product and products therefrom and, in particular, a method of rapidly solidifying a liquid metal foam produced by the incorporation of gas forming agents into an aluminum melt. The aluminum melt may be stabilized to support the creation of liquid metal foam by the addition of metal and/or ceramic additives. The decomposition of the gas forming agents and subsequent expansion of the gaseous products is controlled through the use of a reactor, wherein temperature, pressure and transit time can be adjusted to match the decomposition kinetics of the gas forming agent. The invention allows for the economical production of liquid metal foam of uniform cell size that can be continuously cast into sheet, plate and profile sections. Such metal foam products may be used in structural, thermal and acoustic applications.