Fabrication and characterization of aluminum foam reinforced with nanostructured γ-Al2O3 via friction stir process for enhanced mechanical performance

Abstract This study focuses on the fabrication and characterization of aluminum foam reinforced with nanostructured γ-Al 2 O 3 , utilizing AA5083 plates. The fabrication process involved the integration of TiH 2 foaming agent particles and reinforcing nanoparticles via the friction stir process (FSP), resulting in the creation of precursor specimens. Subsequently, a separate foaming stage was conducted within a laboratory furnace. The integration of these particles was achieved through the machining of parallel grooves in a single aluminum plate. The initial phase of the experimental study focused on investigating the effect of varying amounts of the foaming agent. Large-scale foams were then produced, achieving a medium porosity of 70%. Electro-discharge machining was employed to prepare specimens for compression testing to analyze their stress–strain response. The results revealed a plateau stress of 27 MPa, a relative Young’s modulus of 4.44 × 10 −3 , and an energy absorption close to 17 MJ/m 3 at 50% strain. Significantly enhanced plateau stress was observed in the manufactured reinforced aluminum foam compared to similar foams produced through conventional methods.