Coupling Effect of Porosity and Cell Size on the Deformation Behavior of Al Alloy Foam under Quasi-Static Compression

Closed-cell AlCu5Mn alloy foam with porosity range of ~45–90% were fabricated by the melt-foaming route. The pore structure of the fabricated Al alloy foam was analyzed and the coupling effect of porosity and cell size on the quasi-static compression behavior of the foam was investigated. The results show that the cell size of the foam decreases with the porosity decline from the view of the contribution rate to the porosity and the hierarchical pore structure characteristics becomes obvious when the foam porosity is low; the compression stress–strain curves of the foams with high porosity (>74%) are serrated due to the large cell size being easy to deform and more strain needed to let the stress recover. Meanwhile, the compression curve of the foams with low porosity (<74%) are smooth without serration, which is attributed to the hierarchical pore structure and less strain needed to let the stress recovery.