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<p>As a porous metallic material with integrated structural and functional properties, the performance of aluminum foam is primarily determined by its porosity and pore structure. However, traditional melt-foaming methods often exhibit poor control over pore structure. In this study, aluminum foam was fabricated using a pressure-controlled foaming technique. Using response surface methodology, foaming temperature, growth pressure, TiH<sub>2</sub> content, and growth time were identified as key parameters to optimize porosity. Performance and structural characterization were performed using the Archimedes drainage method, a universal testing machine, and scanning electron microscopy (SEM). A multiple quadratic regression model was developed, revealing that each factor exhibited an initial increasing followed by a decreasing influence on porosity. The optimal parameters were identified as a foaming temperature of 700&#xa0;°C, a growth pressure of 0.3 MPa, a TiH<sub>2</sub> dosage of 30 g, and a growth time of 10 min, under which the porosity reached 86.4%. The developed regression model demonstrated excellent significance and a high degree of fit. The main, quadratic, and most interaction terms exhibited significant effects on porosity. The optimized process parameters were determined to be a foaming temperature of 707.07&#xa0;°C, growth pressure of 0.32 MPa, TiH<sub>2</sub> dosage of 32.96 g, and growth time of 10.30 min. Under these optimized conditions, the aluminum foam achieved an average porosity of 87.14%, a reduced average pore size of 2.21 mm, an increased roundness of 0.77, and an enhanced compressive peak stress from 5.69 to 7.41 MPa. This study offers theoretical guidance and technical reference for the stable industrial-scale production of high-performance aluminum foam.</p>

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Optimization and Characterization of Aluminum Foam Fabrication via Pressure-Controlled Foaming

  • 期刊论文

  • 发表日期：

    2026年4月20日

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  • Xi Sun,
  • Qingfu Zhang,
  • Fudong Wang,
  • Quanqing Zhang,
  • Jianping Wang,
  • Weina Han

摘要

As a porous metallic material with integrated structural and functional properties, the performance of aluminum foam is primarily determined by its porosity and pore structure. However, traditional melt-foaming methods often exhibit poor control over pore structure. In this study, aluminum foam was fabricated using a pressure-controlled foaming technique. Using response surface methodology, foaming temperature, growth pressure, TiH2 content, and growth time were identified as key parameters to optimize porosity. Performance and structural characterization were performed using the Archimedes drainage method, a universal testing machine, and scanning electron microscopy (SEM). A multiple quadratic regression model was developed, revealing that each factor exhibited an initial increasing followed by a decreasing influence on porosity. The optimal parameters were identified as a foaming temperature of 700 °C, a growth pressure of 0.3 MPa, a TiH2 dosage of 30 g, and a growth time of 10 min, under which the porosity reached 86.4%. The developed regression model demonstrated excellent significance and a high degree of fit. The main, quadratic, and most interaction terms exhibited significant effects on porosity. The optimized process parameters were determined to be a foaming temperature of 707.07 °C, growth pressure of 0.32 MPa, TiH2 dosage of 32.96 g, and growth time of 10.30 min. Under these optimized conditions, the aluminum foam achieved an average porosity of 87.14%, a reduced average pore size of 2.21 mm, an increased roundness of 0.77, and an enhanced compressive peak stress from 5.69 to 7.41 MPa. This study offers theoretical guidance and technical reference for the stable industrial-scale production of high-performance aluminum foam.