Fabrication of aluminum foam stabilized by copper-coated carbon fibers

Short copper-coated carbon fibers were used as novel stabilizer for aluminum foam. Aluminum foams containing 0.35, 1.0, 1.7 vol.% copper-coated carbon fibers were fabricated by a melt route. Foaming behavior and microstructure of these foams were observed. Results show that copper-coated carbon fibers can stabilize aluminum foam by preventing cell wall rupture and reducing coalescence. The fibers are mostly located inside cell wall and form a network structure, which can generate separating force and prevent cell wall from rupture. The volume fraction of copper-coated carbon fibers needed to stabilize aluminum foam is as low as 0.35 vol.%, and the foam is more stable when more fibers are used.