Aluminum foam composite materials are gaining traction in aerospace and automotive industries for their advantageous properties including low density, high energy absorption capacity, and corrosion resistance. For industrial applications they are most commonly used in the form of sandwich panels with a foamed core and solid aluminum sheets. For molded aluminum foam parts different casting technologies have been developed as well. Additive manufacturing techniques offer distinct benefits over traditional methods - for eyample enabling the fabrication of geometrically complex components without costly tool production. Additive methods for producing aluminum foam are already described in the scientific literature – mostly using laser-based methods like selective laser melting or laser powder deposition welding. Direct Energy Depoision via electric Arc (DED-Arc) also known as Wire Arc Additive Manufacturing (WAAM) processes stand out for multiple reasons: Usage of more cost effective technology (MIG welding power sources instead of lasers) and consumables (wire electrodes instead of metal powder), high build-up rates and the ability to print on already existing aluminum structures.

This paper introduces a method for manufacturing aluminum foam structures using an additive DED-Arc process, standard filler materials and a hydrogen-infused shielding gas. Emphasis is placed on the technological concept, the structure and the mechanical properties of additively manufactured aluminum foams.