Metal foams are cellular structures fabricated by gas filled pores in a metal matrix. Metal foams possess exceptional mechanical as well as physical properties. The low thermal conductivity property of metal foam makes them a great choice for flame arrestor materials and heat exchangers. High stiffness and impact absorbing capabilities of the metal foams are utilized in high-speed ballistic testing. Tensile strength and corrosion resistance properties of metal foams are exploited in orthopedic applications. Sound damping characteristics are used in automotive industry for sound damping applications. For stiffening of structures, metal foams are used because of their high stiffness. Aluminum metal foams find numerous applications in military, marine and automobile sector. Various processes for fabrication of Aluminum metal foam are discussed in this review. Metal foam manufacturing is problematic due to the existence of solid, liquid, and gaseous phases at various temperatures. Despite the different ways and procedures for producing foamed metals, the foamed metal nevertheless contains flaws and non-uniformities. To increase foam quality, researchers must investigate and comprehend the stability of foam in liquid metals, which will aid in the development of more dependable and repeatable foam metal manufacturing procedures. The best way for producing aluminum metal foam for mechanical applications is found in this review.

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Dr. Zahid Akhtar Khan