How We Make it

Alusion is a form of Stabilized Aluminum Foam. The patented process for creating Alusion starts with a metal matrix composite – an aluminum alloy to which ceramic particles have been added. Once melted, the aluminum alloy is poured into a foaming box. Gas bubbles exiting immersed rotating impellers (a component of the air injection system) form the foam. The foam collects on the surface of the molten material, where it can be continuously drawn off to form a sheet. The foam structure is predominantly closed cell. The cell size is controlled by the gas flow rate, impeller design and impeller rotational speed. The rate and means by which the gas is introduced can be varied to produce foams with varying densities.