Aluminum matrix syntactic foams with low-cost porous ceramic spheres of diameters between 0.25 and 4 mm have been manufactured by pressure infiltration casting. These syntactic foams were homogeneous in structure and had densities as low as half of the density of the Al matrix. The mechanical response of the four types of syntactic foams with different sphere sizes and densities under static and dynamic conditions have been investigated. The plateau strength and thus the amount of energy absorption of the syntactic foam are largely determined by the volume fraction of Al and to a lesser extent by the mechanical properties of the ceramic spheres in the foam. Compared with the Al foams with similar Al volume fractions, the syntactic foams had better energy absorption capacity, especially under impact conditions.

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