Quasistatic deformation analysis of melt-based molded die-cast open-cell aluminum alloy foam

The metal foams behavior significantly depends on the method applied for its manufacturing. Present work investigates the mechanical quasistatic three-point and compressive deformation behavior of molded die-cast open-cell Aluminum Alloy foam (OCAF). Different span lengths and loading velocities were selected for the experimentation. The deformation behavior of the OCAF was studied and the effect was correlated with different theories available for foam deformation. The plastic behavior of OCAF was also studied using a compression loading–unloading experiment at different stress and strain values. Microstructural study and phase analysis were carried out at the cell wall surfaces using fractography to establish the cause of brittle failure dominant in the foam. Further, micro-CT analysis was used to study the cell deformation in the bulk material and the role of micropores and macro-pores.