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Metal foam is a high-porosity engineering material which has many outstanding properties such as light weight, high specific strength and stiffness, large energy absorption during impact and good thermal transportation. The impregnation of metal foams with polymers produces a new types of composites such as interpenetrating phase composites (IPCs) or co-continuous composites due to the interconnection on a macroscopic level of individual phases as a co-continuous 3-D network. The coexistence of the metal and polymer phases allows each to contribute its prominent properties to the composite. This innovative composite material is a potential candidate for applications in the automotive and aerospace industries. The present study aims to develop two IPCs from open-cell Al foams of 20 ppi impregnated with silicone or epoxy resin. The compressive behavior and energy absorption characteristics of IPCs are also examined and compared. The results show that although both IPCs have a similar foam structure with similar density, the disparities in the properties of impregnated polymers lead to distinct mechanical properties. The combination of Al foam and polymers, both silicone and epoxy resin, results in IPCs stiffer than either of the two individual materials by themselves. Higher stiffness was found in IPCs with epoxy resin, owing to brittle nature of the resin. Energy absorption capacity was also increased when compared with the original Al foam.

Structure and mechanical properties of ADC 12 Al foam-polymer interpenetrating phase composites with epoxy resin or silicone