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<p>AlSiMg alloy has been found to enable the direct shaping of complex aluminum foam components via casting foaming methods, significantly broadening the processing and application potential of aluminum foams. This study comparatively analyzes the energy absorption capacity and deformation modes of such foams against traditional AlCa foams prepared by melt foaming, utilizing quasi-static compression tests coupled with digital image correlation (DIC). Compared to AlCa foams, the initial peak stress and plateau stress of AlSiMg foams at the relative density of 0.27 are 1.9 and 1.3 times higher, respectively. This enhancement was attributed to hard-phase reinforcement (Mg<sub>2</sub>Si, Si, and MgAl<sub>2</sub>O<sub>4</sub>) in combination with a larger cell&#xa0;size, which also induced brittle fractures during compression. The collective influence of the hard phases and cell structure leads to fluctuations in the stress–strain curve. Stress–strain curves of AlCa foams exhibited smoother, and their energy absorption capacity was demonstrated better at lower densities (under 0.24) due to their better plasticity of the matrix. DIC results revealed distinct deformation modes of the two kinds of aluminum foams. The AlSiMg foam followed a "Hard-phase support—Brittle fracture" mechanism, with crack propagation along hard-phase interfaces, while the AlCa foam exhibited "Plastic coordination—Progressive buckling", enabled by uniform cell distribution and ductile matrix. Therefore, the alloy matrix critically governs the foam performance under the same relative density, with hard phases enhancing strength but weakening ductility in AlSiMg foams. This work provides fundamental insights for designing matrix alloys to tailor foam properties for energy-absorbing applications, highlighting the trade-offs between strength and toughness in aluminum foams.</p>

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Effect of alloy matrix on the quasi-static mechanical properties and deformation mechanisms of aluminum foams

  • 期刊论文

  • 发表日期：

    2026年1月10日

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  • Mingfang Zhu,
  • Ningzhen Wang,
  • Wensheng Fu,
  • Peng Zhang,
  • Ruyuan Yang,
  • Liang Tang,
  • Xiang Chen

摘要

AlSiMg alloy has been found to enable the direct shaping of complex aluminum foam components via casting foaming methods, significantly broadening the processing and application potential of aluminum foams. This study comparatively analyzes the energy absorption capacity and deformation modes of such foams against traditional AlCa foams prepared by melt foaming, utilizing quasi-static compression tests coupled with digital image correlation (DIC). Compared to AlCa foams, the initial peak stress and plateau stress of AlSiMg foams at the relative density of 0.27 are 1.9 and 1.3 times higher, respectively. This enhancement was attributed to hard-phase reinforcement (Mg2Si, Si, and MgAl2O4) in combination with a larger cell size, which also induced brittle fractures during compression. The collective influence of the hard phases and cell structure leads to fluctuations in the stress–strain curve. Stress–strain curves of AlCa foams exhibited smoother, and their energy absorption capacity was demonstrated better at lower densities (under 0.24) due to their better plasticity of the matrix. DIC results revealed distinct deformation modes of the two kinds of aluminum foams. The AlSiMg foam followed a "Hard-phase support—Brittle fracture" mechanism, with crack propagation along hard-phase interfaces, while the AlCa foam exhibited "Plastic coordination—Progressive buckling", enabled by uniform cell distribution and ductile matrix. Therefore, the alloy matrix critically governs the foam performance under the same relative density, with hard phases enhancing strength but weakening ductility in AlSiMg foams. This work provides fundamental insights for designing matrix alloys to tailor foam properties for energy-absorbing applications, highlighting the trade-offs between strength and toughness in aluminum foams.