In the current study, a first attempt at using aluminum flakes for the manufacture of open-cell aluminum foams with the space holder method is presented. The method involves powder mixing, compaction, leaching, and sintering processes. Saccharose particles were used as space holders, and multiple parameters were investigated to optimize the manufacturing processing route in order to produce high-quality open-cell aluminum foams with a simple, economic, and environmentally friendly method. The implementation of aluminum flakes leads to foams with 80 vol.% porosity, an excellent internal open-cell porous structure, low green compaction pressures, and does not require the use of binding additives.
Keywords: aluminum flakes; aluminum foam; metal foam; saccharose particles; space holder method.