Effect of the Grain-Refining of A356 Aluminum Alloy Closed-Cell Foams on the Mechanical Compression Properties

Aluminum metallic foams are lightweight porous materials characterized by low density, high stiffness, and remarkable energy absorption capacity. The mechanical performance of these materials strongly depends on the microstructure of the metallic matrix and the porous structure. In this study, closed-cell A356 aluminum foams were produced by the Alporas melt-foaming method using barite (BaSO4) as a thickening agent and calcium carbonate (CaCO3) as a foaming agent. The effect of grain refinement on the microstructure and energy absorption behavior under quasi-static compression was investigated. Grain refinement was evaluated by adding four concentrations of Al-5Ti-1B master alloy (0.02, 0.05, 0.08, and 0.10 wt.%) to the unrefined foam. The addition of Al-5Ti-1B reduced the secondary dendrite arm spacing (SDAS) from 41.85 µm to a minimum of 32.96 µm at 0.05 wt.%, producing stronger and more homogeneous cell walls that increased the plateau stress from 0.525 to 1.549 MPa and the energy absorption capacity from 0.299 to 0.735 MJ/m3—improvements of 195% and 145%, respectively. The energy absorption efficiency analysis confirmed that any refiner concentration improved the compressive performance compared to the unrefined foam. In addition, the energy absorption efficiency (E) and the ideality energy absorption efficiency (I) confirm that the refinement of the dendritic structure through Al-5Ti-1B addition strengthens the foam cell walls, improving their mechanical behavior and performance as an energy-absorbing material under quasi-static compression.