An attempt has been made to develop a high profit recycling process for aluminium scraps, by which high performance aluminium foam materials could be produced directly from scrap. This is based on the fact that oxides on the surface of aluminium scrap can act as a viscosity thickener, the basic necessity for molten processes of aluminium foams. The main emphasis of this study is on optimisation of the process variables for manufacturing aluminium foam materials by direct foaming of remelted aluminium scrap.
