Compressive response of Al-foams produced via a powder sintering process based on a leachable space-holder material

Al-foams were manufactured by using powder metallurgy technology based on a leachable space-holder material. The method involved mixing and compaction, leaching and sintering processes. Depending on the volume fraction and the size of the space-holder material, the porosity could be controlled in the range of 50–75%. Sintering temperature strongly affected the cell walls microstructure of the foams. Quasi-static compressive tests also indicated that the mechanical behaviour of the produced Al foam was affected by the sintering temperature and the particle size of the metal powder. Liquid state sintering yielded to higher compression properties while reduction in the powder size of metal increased considerably the yield stresses. The deformation behaviour of the Al-foams was governed by the porosity. The stress–strain response of the Al-foams was in good agreement with the Gibson–Ashby model. Good reproducibility and predictability of compressive properties was achieved especially in foams having small pore size.