On the mechanical performance of closed cell Al alloy foams

The mechanical properties of three different commercially available closed cell Al alloys all made by foam casting are examined. The objective is to assess the roles of cell morphology and of imperfections in governing the basic properties: stiffness, yield strength and fracture resistance. This assessment provides goals for manufacturing strategies that enable attainment of good mechanical performance with affordable process technologies. A prevalent role of curves and wiggles in the cell walls on stiffness and strength (anticipated by models) is affirmed by the present measurements. Systematically larger stiffnesses and yield strengths found in tension than in compression are consistent with a prominent role exerted by such imperfections. Moreover, foam casting is apparently capable of cell morphologies that impart properties approaching the best achievable values for an isotropic closed cell solid, devoid of imperfections. There are associated implications for performance and affordability. Fracture measurements indicate crack growth occurring along the cell walls by a mechanism analogous to the plastic tearing of thin sheets. The crack growth resistances are in the range of 1 kJm⁻². This mechanism infers a toughness that scales with the cell wall thickness and its yield strength.