Open-cell aluminum foams were manufactured by a sponge replication technique having a total porosity of ~90%. The influence of the thermal processing conditions such as atmosphere and temperature on the cellular structure, phase composition porosity, thermal conductivity, and compressive strength of the foams was studied. It was found that the thermal processing of aluminum foams in Ar at temperatures up to 800 °C led to aluminum foams with a reduced strut porosity, a lower amount of aluminum oxide, a higher thermal conductivity, and a higher compression strength, compared to foams thermally processed in air. These results were explained by the lower amount of aluminum oxide after thermal processing of the foams.

Polymer derived ceramic foams were prepared with the replica method using filler free and filler loaded polysiloxane containing slurries for the impregnation of open celled polyurethane foams. A significant change in mechanical strength, porosity and surface energy, i.e., wettability after thermal treatment between 130 °C (crosslinking) and 1000 °C (pyrolysis) in argon atmosphere was observed. While low-temperature pyrolyzed foams are elastic and hydrophobic, foams pyrolyzed at high temperatures are brittle and hydrophilic, and they possess higher compression strength. Changes of these properties were correlated with the polymer-to-ceramic transformation.

The present work describes the combination of the well-established dispersion infiltration of the hollow struts in reticulated porous ceramics (RPCs) and the salt solution infiltration of the remaining strut porosity. This approach is applied on alumina foams, which are loaded subsequently with a dispersion of sub-micrometer alumina particles and a ZrO(NO₃)₂ solution. The zirconyl nitrate is converted into a ZrO₂ transformation toughening phase during the final sintering step. As a consequence of the complex microstructure evolution during the consecutive infiltration cycles, the reinforcement phase concentrates selectively at the weak spots of RPC structures—namely, the hollow strut cavities and longitudinal cracks along the struts. As a consequence, a severe improvement of the compressive strength is observed: The average compressive strength, normalized to a porosity of 91.6 vol.%, is 1.47 MPa for the Al₂O₃/ZrO₂ infiltrated foams, which is an improvement by 40% with respect to alumina-only loaded foams (1.05 MPa) or by 206% compared to uninfiltrated alumina RPCs (0.48 MPa). The compressive strength results are correlated to infiltration parameters and the properties of the infiltration fluids, for example the rheological behavior and the size of the Zr solute species in the respective ZrO(NO₃)₂ solution.