Compressive mechanical properties of low-cost, aluminium matrix syntactic foams

Abstract

Metal matrix syntactic foams (MMSFs) are high-performance foams consisting of a light-weight matrix and a set of porous fillers. The obstacle against the wide-spreading of MMSFs is their high cost (raised by the fillers’ price). In this study, low-cost MMSFs have been developed and characterised in the structure – mechanical properties relationship aspect. The MMSFs were produced by low-pressure infiltration from the combination of two matrices (Al99.5, AlSi9MgMn) and three nominal diameters (4, 8 or 11 mm) light expanded clay agglomerate particles (LECAPs). The density of the MMSFs was 1.38–1.53 g.cm−3. The mechanical properties were characterised by compressive tests. The effects of the alloying and T6 heat treatment were evaluated. Exponential relationships were found between the LECAPS’ fracture force values and the strength and absorbed energy values. The produced MMSFs proved equal or higher properties than the top materials investigated in the literature. The produced MMSFs showed plastic collapse failure.