A novel single-step method for fabrication of dense surface porous aluminum

A new manufacturing process was developed for functionally graded porous Al foams. Morphological variations were monitored by scanning electron microscopy. Mechanical properties were measured by compressive tests. Results indicated that the maximum temperature of 773 K and minimum interior porosity of 60% are the best conditions. Scanning electron microscope (SEM) images show a strong connection between Al particles with high necking radius. Micro-hot molding of Al particles in the space between salt particles is probably responsible for porosity formation.