Influence of the space holder particles morphology on the structure and mechanical properties of aluminum foams manufactured by infiltration

Aluminum foams excel as versatile materials by combining porous structures with aluminum alloys properties. The infiltration method provides precise control over pore size and distribution, but depends on space holder particles (SHP) characteristics. This study examines the influence of SHP morphology on the structural and mechanical properties of infiltrated aluminum foams. Al-319 alloy was used with NaCl SHPs (∼5 mm of equivalent diameter) with three morphologies: spherical, ellipsoidal, and irregular. Structural characterization included density measurements, image analysis, and computed tomography. Uniaxial compression tests revealed that foams with granulated pores had the lowest properties (E = 1.15 GPa, σ pt = 13.19 MPa, E abs = 7.51 MJ/m³), while spherical pores maximized energy absorption (10 MJ/m³) due to improved load distribution.