Fabrication of aluminum (AlSi10Mg) matrix particle (Ti and Zr) reinforced composite foam using directed energy deposition

•This study investigates fabrication of particle reinforced composite foam (PRCF) using AlSi10Mg and foaming agents (TiH2 and ZrH2).•Decomposition of TiH2 and ZrH2 can not only form large pores, but also microscopic Kirkendall voids.•Many intermetallic compounds formed by reaction of aluminum and foaming agent are observed.•Improved wear resistance of PRCF is attributed to high modulus of elasticity and hardness of residual particles.•Oxide film generated during the foaming caused interlayer defects.