In this study, we analyzed the structural and mechanical properties of aluminum foams fabricated using aluminum powders of varying sizes and mixtures. The effects of sintering and pore structure at each size on the integrity and mechanical properties of the foams were investigated. Structural characteristics were examined using scanning electron microscopy and micro–computed tomography, while mechanical properties were evaluated through compression testing. The experimental results demonstrated that smaller powder sizes improved foam integrity, reduced porosity and pore size, and resulted in thinner cell walls. In combination, these effects increased compressive strength as the powder size decreased. The findings of this study contribute to the understanding and improvement of the mechanical properties of aluminum foams and highlight their potential for use in a wide range of applications.

1. Introduction
2. Experimental Procedure
    2.1 Foam Manufacturing
    2.2 Microstructure Analysis
    2.3 Mechanical Properties
3. Results and Discussion
    3.1 Powder and Foam Measurement
    3.2 Microstructure Measurement Using SEM
    3.3 Microstructure Measurement Using Micro–CT
    3.3 Compression Test
4. Conclusion
Funding
Conflict of Interest
Data Availability Statement
Author Information and Contribution
Acknowledgments
References

• Seunghyeok Choi(Department of Advanced Materials Engineering, Jeonbuk National University, Jeonju 54896, Republic of Korea)
• Sungjin Kim(Department of Advanced Materials Engineering, Jeonbuk National University, Jeonju 54896, Republic of Korea)
• Jae–Gil Jung(Department of Advanced Materials Engineering, Jeonbuk National University, Jeonju 54896, Republic of Korea)
• Seung Bae Son(Department of Advanced Materials Engineering, Jeonbuk National University, Jeonju 54896, Republic of Korea) Corresponding author
• Seok–Jae Lee(Department of Advanced Materials Engineering, Jeonbuk National University, Jeonju 54896, Republic of Korea) Corresponding author
• Tae–Young Ahn(Agency for Defense Development, Yuseong, P.O. Box 35–41, Daejeon 305–600, Republic of Korea)
• Yu–Song Choi(Agency for Defense Development, Yuseong, P.O. Box 35–41, Daejeon 305–600, Republic of Korea)