Abstract
Porous aluminum is a lightweight material with high energy absorptivity. In this study, porous aluminum/dense steel sandwich panel was fabricated by friction stir processing (FSP) route. In the FSP route, mixing a blowing agent into aluminum and bonding the aluminum precursor to dense steel plate can be conducted simultaneously. In the manufactured porous aluminum/dense steel sandwich panel, diffusion bonding was realized and Fe-Al intermetallic compound was formed at the interface of porous aluminum and dense steel. Moreover, the sandwich panel was fractured at a porous aluminum part.