Method for producing foamed aluminum products by use of selected carbonate decomposition products

A method of making an aluminum foam product comprising:

• adding reactive gas producing particles to a molten aluminum alloy that is at a temperature above the decomposition temperature of the reactive gas producing particles so that, at least a portion of the reactive gas producing particles produce reactive gas of carbon dioxide;
• reacting the carbon dioxide with the molten aluminum alloy at a sufficient melt temperature of the alloy, sufficient ratio of the reactive gas producing particles to the molten aluminum alloy, sufficient residence time and sufficient particle size of the reactive gas producing particles so as to produce at least Al203, CO and a foamable suspension, wherein the foamable suspension is resistant to coalenscence and drainage;
• retaining a portion of the reactive gas producing particles as a chemical foaming agent;
• mixing the foamable suspension with the chemical foaming agent to form an inoculated foamable suspension;
• foaming the inoculated foamable suspension;
• and
• forming a foamed aluminum product.