Annealing Time Effect on the Microstructure, Phase Evolution, and Magnetic Properties of Self-Foaming AlCuFe Alloy

The self-foaming method offers a promising approach for producing AlCuFe metallic foams without the need for external foaming agents. Although it is well established that both alloy composition and heat treatment play a fundamental role in pore formation, the specific influence of annealing time on the resulting microstructure and physical properties remains insufficiently explored. In the present study, the effects of annealing time on the microstructure, phase evolution, and magnetic properties of self-foaming Al58Cu27Fe15 alloys are investigated. Metallic foams were synthesized using the self-foaming method, heat-treating the samples at 850 °C for 6, 9, 15, and 24 h. X-ray diffraction (XRD), differential thermal analysis (DTA), and scanning electron microscopy (SEM) reveal that prolonged annealing increases porosity, reaching 64% and 61% after 15 and 24 h, respectively. The porosity formation mechanism was attributed to a peritectic reaction involving the liquid metastable τ phase and the solid λ and β phases. Magnetic measurements indicated complex behavior consistent with the Curie–Weiss law, influenced by phase composition and interactions between Coulomb forces, Hund’s rule exchange, and Fe 3d–Al s, p orbital hybridization.