| Summary: | Magnesium alloys have considerably lower density than the aluminum alloy matrices that are typically used in syntactic foams, allowing for greater specific energy absorption. Despite the potential advantages, few studies have reported the properties of magnesium alloy matrix syntactic foams. In this work, Al2O3 hollow particles of three different size ranges, 0.106–0.212 mm, 0.212–0.425 mm, and 0.425–0.500 mm were encapsulated in Mg-AZ91D by a sub-atmospheric pressure infiltration technique. It is shown that the peak strength, plateau strength and toughness of the foam increases with increasing hollow sphere wall thickness to diameter (t/D) ratio. Since t/D was found to increase with decreasing hollow sphere diameter, the foams produced with smaller spheres showed improved performance—specifically, higher energy absorption per unit weight. These foams show better performance than other metallic foams on a specific property basis.
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