Morphology of Aluminum Alloy Foams Produced with Dolomite via Partial Sintering of Precursors

Highly expanded, low-cost aluminum-based foams were successfully produced via powder metallurgy using dolomite as foaming agent. Nickel additions (5-15 wt.%) were explored in order to reduce the temperature disparity between dolomite decomposition and the melting range of the metallic matrix. Specific Al-Ni compositions provide appropriate viscosities for effective encapsulation of CO2 gas released during dolomite decomposition. A partial sintering step of compacted precursors was introduced prior to foaming, which resulted in high porosity levels (similar to 86%) and significant volume expansion (similar to 250%) in the final product. The partial sintering technique was a key determining factor in obtaining stable, highly expanded cellular structures with homogeneous pores, averaging 3 mm in size and being morphologically comparable with ALPORAS(TM) foams.