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Bi-continuous alumina/aluminium composites were made by infiltrating an alumina preform which had the structure of a reticulated ceramic foam. The low density preforms were prepared from a polyurethane suspension of alumina powder which was pyrolysed and sintered after foaming. Higher density preforms consisted of ceramic foams with open cells. All these preforms were infiltrated with 6061 aluminium alloy using a modified squeeze caster fitted with a vacuum system and fine control of speed and pressure. The microstructure of the preform fitted an established relationship between the ratio of window diameter to cell diameter (k) and void volume fraction (V p ). Low k foams were infiltrated fully but on cooling below the solidus, interfacial debonding took place due to differential thermal contraction. This was overcome by modifying the processing conditions. High k foams which had high fractional porosity, retained sound interfacial bonding. The composites possess higher elastic modulus than conventional MMCs with a homogeneous reinforcement distribution at a given volume fraction. The loss of electrical conductivity is negligible in the lower volume fraction range because of the three dimensionally continuous aluminium phase. The experimental results are compared with a number of theoretical predictions.

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