"Lightweight Metal Foams with Tailorable Structure and Properties"

The efficient, high-yield, and low-cost production of lightweight energy-absorbing vehicle components would enable both energy and cost savings. This project will develop a cost-effective manufacturing technology for the high-volume production of metal foams and foam-filled structures that have a uniform, consistent, and well-controlled cell structure and properties. A variety of metal foams with density and anisotropy tailored to the desired end use can be produced by this technology. The technology will allow the precise control of cell diameter, which may be accurately pre-assigned in the range from a tenth of millimeter to several millimeters in size. In particular, the energy-absorption characteristics of components fabricated from the proposed foams can be tailored to specific applications through the control of their porosity, cellular structure, and anisotropy. Commercial Applications and other Benefits as described by the awardee: Utilization of foam-filled components in vehicles should result in reduced weight and enhanced safety. Particular areas where the metal foams could be exploited to beneficial effect are the side members, the boundaries of the floor of the passenger compartment, and in the region of the sills and pillars. Open-cell foams also could be utilized for the production of sound insulation panels, highly efficient filters, heat exchangers, catalyst carriers, high temperature insulation, transpiration cooled systems, and many other parts.