A Novel Technique to Produce Ultra-Porous Metallic Foams through Thermal Reduction of Nano-Particle Oxide

70930 Improved manufacturing processes and materials are needed to build more energy-efficient, light weight materials metallic foams for transportation systems. This project will develop a manufacturing process for a wide range of porous metal structures. The technology will allow metal foam structures to be fabricated into a wide range of geometry, porosity, and dimensions. In addition, the process will be less expensive than other technologies, amenable to large volume manufacturing, and allow virtually any metal or alloy powders to be made into a metal foam or porous metal product. Phase I will establish the relationship between the processing methods and the microstructure and properties of the porous metal foams (Ni, Cu) in various applications such as lightweight structural components and filters. Commercial Applications and Other Benefits as described by the awardee: The new process should lead to self-supporting, stiff, super lightweight panels for building and transport; impact energy absorption parts for cars, lifting, and conveying systems; non-flammable ceiling and wall panels with improved thermal and sound insulation; compressor casings; motorcycle exhausts and frames; heat exchangers; filters; and catalysts.