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Aluminum Foam


Development of an Efficient Technology for Aluminum Foam Materials Production

Tech Area / Field

  • MAT-ALL/High Performance Metals and Alloys/Materials
  • CHE-IND/Industrial Chemistry and Chemical Process Engineering/Chemistry

8 Project completed

Registration date

Completion date

Senior Project Manager
Ryzhova T B

Leading Institute
VNIIEF, Russia, N. Novgorod reg., Sarov

Supporting institutes

  • All-Russian Institute of Light Alloys, Russia, Moscow


  • Hahn-Meitner Institut Berlin, Germany, Berlin\nDepartment of Materials Science and Engineering, Northwerstern University, USA, IL, Evanston IL

Project summary

The present project is focused on the development of a pilot technology to produce aluminum alloys capable of foaming at thermal treatment of dispersed materials in the form of particles.

Aluminum foam production technology and applications are under rapid development in various industrial branches of many countries (Japan, Canada, the USA, Germany).

The promising uses of aluminum foam are based on its unique properties, namely:

– low density (0.3 to 1.5 g/cm 3);

– high soundproofing (noise reduction by 30-40 decibels within a range from 800 to 2,000 Hz);
– high shock-absorption (damping capacity);
– environmental safety;
– low heat conductivity (20 to 30 times as low as that of aluminum);
– fire resistance.

Aluminum foam production technologies are based on two approaches:

– the first, so-called casting approach, involves foaming of a bath filled with aluminum melt by admixing viscosifier particles and foaming agents followed by cooling down the foam in a casting mold;

– the second, powder approach, involves fabrication of a semi-finished product of mixed powders (aluminum and foaming agent), which is then molded by plastic deformation. The molded workpiece is then treated with heat (foaming at the foaming agent’s decomposition temperature) and aluminum foam is thus produced.

The greatest challenge on the way toward wide aluminum foam utilization is price reduction and enhanced ease of machining. This can be achieved by developing a respective technology for dispersed foaming agent-containing material production.

The present project is aimed at the development of an efficient technology to produce dispersed foaming agent-containing aluminum-based material.

The anticipated outcome of this project is production of cost-efficient and rather complex-shaped aluminum foam articles.

The present project is to be carried on at the Russian Federal Nuclear Center – All-Russian Research Institute of Experimental Physics (Sarov, Nizhny Novgorod region) on the basis of the Public Joint-Stock Company – All-Russian Institute of Light Alloys (Moscow).


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