Novel Technology for High Energy-Absorbing Metallic Foams and Structural Components

"The goal of this Phase II SBIR program is to optimize and scale-up the innovative technology for fabrication of metal foams with random and oriented porous structure. The technology enables accurate control of porosity, size and orientation of pores. Thenear-net-shape sandwich, shell, and tubular structures with foam cores can be produced in one step, which reduces the cost of manufacturing and makes them commercially competitive. Along with the ability to absorb mechanical energy, they can perfectlydissipate heat energy. The unique combination of low density, highly developed inner surface and low pressure drop of the metal foams produced by the developed technique makes possible their multifunctional use. Thermomechanical properties of these foamssuggest their implementation in ultralight structures and for heat dissipation media. The optimized technology will be used for fabrication of dual-use aluminum foam structures, which combine functions of lightweight energy-absorbing components and heatexchangers. The stainless steel foams with oriented channels will be utilized as cryocooler regenerators for infrared sensor systems."