Sound absorption performance and mechanism of aluminum foam with double-layer structures of conventional and porous cell walls

Open-cell aluminum foam exhibits sound absorption valleys in the 2500-4000 Hz range, reducing its sound absorption performance in the 800–6300 Hz range. This paper prepared a novel aluminum foam with a double-layer structure using the infiltration casting method, and its pore structure, sound absorption performance, acoustic model, and sound absorption mechanism are investigated. The double-layer structure consists of a conventional pore (CP) layer with a single pore size of 250 μm or 600 μm and a porous cell wall (PCW) layer with double pore diameters of 250 μm and 600 μm. As the thickness ratio between the CP and PCW layers decreases, the acoustic absorption valley value of the double-layer structure increases when combined with a small-pore CP layer. In contrast, it decreases slightly when combined with a large-pores CP layer. The double-layer structure reaches a sound absorption valley value and average sound absorption coefficient of 0.912 and 0.902, respectively. The double-layer structure's sound absorption valley value is better than that of a homogeneous structure, improving sound absorption performance. A Lu modified model is established to characterize the sound absorption of the double-layer structure, which closely matches the experimental results. The modified model further analyzed the vital geometrical parameters affecting the absorption valleys. Acoustic impedance analysis shows the enhanced sound absorption valleys are due to: 1) Gradient acoustic impedance reduces sound reflections at the air-structure interfaces and increases secondary reflection at the interfaces in the structure; 2) The series–parallel configuration increased the resonance peak bandwidth, while the dual-sized resonance cavities regulated the resonance peak frequency.