Development of Low Cost Manufacturable Shape Memory Foams for Automotive Shock Energy Adsorption

78199S In automobile crashes, better survival rates and less trauma could be improved by dramatically reducing the shock forces experienced by the vehicle. This project addresses this problem by developing light-weight, TiNi-based, porous metal foams for automotive shock absorption. Previous work has demonstrated that large amounts of shock absorption (up to 10 times) are possible with porous TiNi produced by self-propagating, high-temperature synthesis. However, in order to meet automotive cost and shock requirements, an even lower density foam will need to be produced. In Phase I, low density (10% dense) TiNi foams will be fabricated and tested under shock loading for automotive industry compliance. The foams will be characterized using standard mechanical testing and shock loading techniques. Based on reduced mass via high porosity, and an comparitively inexpensive technique, cost and shock absorption goals set by partners Hughes Research Lab and General Motors will be met and a development roadmap to integrate this technology into future vehicles will be developed. Commercial Applications and Other Benefits as described by the awardee: Commercial applications not only include both automotive crash survival assemblies but also biomedical implants and military tanks. In the automotive arena, the TiNi foams offer a lower-cost shock damping solution than other alloys, such as aluminum, and therfore represent a new means to improve vehicular survival rates. For biomedical implants, TiNi is a biomaterial with excellent osteointegration performance. For tanks, the material could be used in track shoe assemblies as a land mine shock attenuation system. The total market is on order of $300 million.