Mechanical properties of a density-graded replicated aluminum foam

The compressive mechanical properties of uniform and density-graded Al-6061 foams, produced by replication of polymer foams, are measured. While the uniform foam shows compressive behavior characteristic of conventional (uniform) metallic foams with a near constant plateau stress, the density-graded foam exhibits a smoothly rising plateau stress. This behavior is modeled using a simple series composite model based on semi-empirical scaling relationships for the compressive behavior of uniform foams.