<p>In the present study, FSP is used to fabricate the AA8090 metal foam by uniform distribution of TiH₂ in the alloy's metal matrix. The effect of tool rotational speed, tool traverse speed, tool tilt angle, heat treatment temperature, and heat treatment time is analyzed on the density and porosity of the AA8090 foam. These developments are especially beneficial in the defense, automotive, and aerospace sectors, where high strength-to-weight ratios and the capacity to absorb energy are critical. The integration of TiH₂ foam into AA8090 through optimized FSP can lead to the development of cost-effective, high-performance materials for crash-resistant panels, vibration dampers, and thermal insulation components. Taguchi optimizes the value of the process parameters- ANOVA L27 orthogonal array analysis. The effect of the input variables is scrutinized with the help of an ANOVA table, and their ranks and percentage contribution to the density and porosity of the foam have been evaluated. The Microhardness of the foam is also analyzed, and a combination of various peaks and valleys is determined due to the presence of pores in the solid structure. After uniform mixing of TiH₂, the maximum achieved porosity is 60.15%, whereas the density of the foam is minimized up to 1.0&#xa0;g/cc. The effect of alumina on the pore's quality is also presented, creating an oxide layer around the pores to stabilize them. The presence of reinforced powder has been validated through SEM–EDS analysis.</p> Graphical abstract <p></p>