Shaping of Aluminum Foam during Foaming Process Using Stainless Steel Mesh Mold

In this study, a stainless steel mesh was used as a mold for fabricating aluminum foam with a complex shape during the foaming of a precursor by employing optical heating. From the foaming of the precursor in stainless steel mesh molds with the shapes of an airplane and vehicle, it was shown that aluminum foam with similar shapes to the stainless steel mesh mold can be obtained. No protrusion of the aluminum foam through the mesh openings was observed. A mesh pattern was transferred to the surface of the aluminum foam when a rough mesh was used. In contrast, aluminum foam with a smooth surface was obtained when a fine mesh was used.