Our paper has been accepted for publication in the Journal of Alloys and Compounds. A free download link to our paper is available for the next 50 days. 

Abstract In this research, aluminum tubes were integrated into metal syntactic foam (MSF) to manufacture novel tube-filled foam (TFF) structures. Counter-gravity infiltration casting was used to manufacture TFFs using an innovative single-step process. The density of the resulting TFFs was between 1.79 and 1.91 g cm−3 and thus similar to the density of the surrounding MSF. Microstructural analysis of the interface between tube and MSF indicates no significant chemical reaction. For comparison, MSF reference samples without tubes were produced. Quasi-static compression tests were conducted to determine the mechanical properties of the samples produced. The results indicate that embedded aluminum tubes and surrounding MSF mutually stabilize their deformation. TFF samples compressed with uniform barreling from the center of the sample whereas the deformation of MSFs was localized towards one end of the sample. As a result, TFFs showed superior mechanical performance compared to MSFs.

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