Reproducibility of aluminum foam properties: Effect of precursor distribution on the structural anisotropy and the collapse stress and its dispersion

The porous structure of aluminum foam manufactured through the foaming of precursors containing blowing agent is stochastic in nature, usually with a random distribution of pores of different size and shape, creating difficulties in the modeling and prediction of foam properties. In this study, the effect of the initial location of the precursor material in the mold on the foam structure and compression behavior was investigated. Structural characterization showed that the porosity distribution, surface skin thickness and pore orientation was affected by the location of the precursors in the mold and by the extrusion direction of the precursors. Moreover, compression tests demonstrated a significant effect of the structural anisotropy on the collapse stress and its dispersion. The collapse stress of the foam increased if the loading was performed parallel to the thicker surface skin or parallel to the preferential pore orientation, leading to a 20% difference in collapse stress. The dispersion of the collapse stress could be significantly decreased if the loading was performed with regard to the structural anisotropy.