Various methods of making metallic foams and sponges have been studied, although the materials have not yet been put to commercial use. For foams produced using powder metallurgy, this is largely due to the poor surface quality and limited wear resistance. With thermal spray coatings, however, the foams can be upgraded to lightweight composites with defined surfaces, high wear resistance, and significantly increased strength. In this paper, commercial aluminum foams with closed cells and a closed foaming skin are coated with metal and ceramic layers by means of electric arc and plasma spraying. The coated foams are characterized based on their microstructure and the results of uniaxial compression testing. Paper includes a German-language abstract.

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