Preparation of complex shaped aluminum foam by a novel casting-foaming method

A novel casting-foaming (CF) method based on melt foaming route is proposed in this study to prepare aluminum foam parts with complex shape. A foamable and flowable precursor alloy melt (PAM) was prepared by dispersing pre-oxidized TiH2 particles into a thickened Al-Si-Mg eutectic alloy melt, whose liquidus temperature is compatible with the decomposition temperature of pre-oxidized TiH2. Afterwards, the PAM was poured into a heated mold and foamed to fill the mold cavity, followed by solidification. Particle distribution in the precursor and shaping capacity of the CF method were examined. Results show that TiH2 particles can be well dispersed in the precursor without aggregation. The shaped foam parts with submillimeter scale of arc radii at angle (45 degrees, 60 degrees and 90 degrees) tips were obtained, showing an extreme filling capacity of the CF method. (C) 2021 Elsevier B.V. All rights reserved.