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Aluminum-steel composite metal foams (Al-S CMF) are manufactured using steel hollow spheres, with a variety of sphere carbon content, surface roughness, and wall porosity, embedded in an Aluminum matrix through gravity casting technique. The microstructural and mechanical properties of the material were studied using scanning electron microscopy, energy dispersive spectroscopy, and quasi-static compressive testing. Higher carbon content and surface roughness in the sphere wall were responsible for an increase in formation of intermetallic phases which had a strengthening effect at lower strain levels, increasing the yield strength of the material by a factor of 2, while higher sphere wall porosity resulted in a decrease on the density of the material and improving its cushioning and ductility maintaining its energy absorption capabilities

Effect of Sphere Properties on Microstructure and Mechanical Performance of Cast Composite Metal Foams