Aluminum foam

Aluminum foams
sold by McMaster-Carr

Formed aluminum foam from Wikipedia link

Description

Lightweight metallic sheets usually formed air or gas injected into the molten aluminum. Aluminum foams are very strong, nonflammable and eco-friendly. They have excellent impact absorption and are used for collision protection in transport systems; however, unlike polymer foams, when an impact happens, they remain deformed and can only be used once.

Foamed metals are available both in closed cell and open cell forms.

• Open-celled metal foams are usually replicas produced using open-celled polyurethane foams as a skeleton
• Closed-cell metal foams have been developed since the 1950s, but although prototypes were available, commercial production was started only in the 1990s. They made by injecting a gas into molten metal forming pores, or cells, about 1 to 8 mm in size.

Synonyms and Related Terms

foamed aluminum; metal sponge

Commercial products: Duocel

Applications

• Sound and impact insulation
• Architectural facades
• Lightweight case construction
• Heat exchangers

Physical and Chemical Properties

• Lightweight with high strength to weight ratio
• Density (relative to solid As) = 4-12% is most common
• Compression strength = 367 psi (at 8% relative density)
• Tensile strength = 180 psi (at 8% relative density)
• Melting point = 1220f (660C)

Working Properties

• Carbide- or diamond-tipped blades are required for machining
• Joined by brazing, adhesive bonding, mechanical fasteners, or soldering

Forms and Sizes

• Thicknesses from 1/2" to 2"
• Sheets available 6'x6' or 12'x12' (McMaster-Carr)

Resources and Citations

• Wikipedia: Metal foam Accessed Feb. 2024
• American Elements: Foams
• McMaster-Carr: Aluminum foam