In this study, a novel method formanufacturing aluminum foam sandwich (AFS) panels via self-propagating high temperature synthesis (SHS) has been introduced and investigated. In this method, a powder mixture of metallic aluminum and copper oxide was placed in core–sheet interface. Sandwich panel was then heated under static pressure. During heating, SHS reaction (3CuO+2Al=Al2O3 +3Cu,
H < 0) occurred in the interface. The generated heat from this exothermic reaction caused sheets to join the core by melting the interface and nearby. In order to evaluate the shear strength of the interface, the shear test was applied on manufactured sandwich panels, and its results were compared with those obtained from testing the sandwich panels which were produced by diffusion bonding process. Furthermore, by the aid of energy dispersive spectrometer (EDS) and X-ray diffraction (XRD) analyses, the formation of copper in the core–sheet interface and its diffusion into the sheets and the core were investigated. In addition, by plotting the hardness values of the panels’ sheets across distance, it was found that the generated heat of the exothermic reaction caused a local melting of the panel sheets and the core. These results approved that core to sheet joining inmetal foam sandwich panels took place because of the SHS reaction. Significantly, this newmethod could be applied as a proper and alternative method for production of AFS panels.

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