Fabrication of closed-cell aluminium foams with zirconium silicate

Closed-cell aluminium foams are lightweight structural materials known for their low density, high strength-to-weight ratio, and excellent energy absorption capabilities. These unique properties make them highly suitable for applications in the automotive, aerospace, and civil engineering sectors. In this study, ADC12 aluminium alloy foams were produced using calcium carbonate (CaCO3) as the primary foaming agent. To enhance foam stability and control pore morphology, zirconium silicate (ZrSiO4) particles were added as a thickening agent in the range of 2 to 8 wt.%. The addition of ZrSiO 4 significantly increased the melt viscosity, resulting in better retention of gas bubbles and reduced pore coalescence during the foaming process. Microstructural analysis revealed that ZrSiO4 was uniformly dispersed throughout the metallic matrix, contributing to the formation of a more homogeneous and refined cell structure. Axial compression tests were conducted to evaluate the mechanical performance of the foams. Results showed that increased ZrSiO4 content enhanced compressive strength and energy absorption capacity. This study demonstrates that zirconium silicate is an effective additive for improving both the structural integrity and mechanical properties of closed-cell aluminium foams.