Aluminum Foam


Alcoa is currently determining the technical and economic feasibility of producing porous aluminum products using low value scrap as feedstock material. The goal is to create a new aluminum product using low cost aluminum scrap that is competitive with existing materials in cost and performance, providing continuous production of a sheet product with cell size less than 1 mm.

Aluminum Foam:

  • An aluminum matrix with voids (cells)
  • Cells about 0.5 to 5.0 mm diameter
  • 90% to 70% density reduction relative to aluminum
  • Potential applications as low-cost honeycomb-type structures
  • High mechanical energy absorption
  • High rigidity



  • Fire Resistant
  • Heat Resistant
  • Moisture Resistant
  • Resistant to mildew, fungus and bacteria
  • Impact Resistant
  • Rigidity
  • Sound absorption
  • Noise & vibration damping
  • Electromagnetic wave blockage
  • Lightweight
  • Recyclable


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Related Information

Aluminum foam video

Aluminum foam video
 view an interview and demo with Alcoa scientists Scott Harris and Dan Bryant


Aluminum foam white paper

Aluminum foam white paper