Duocel® Metal Foams with Spatially Varying Properties

ERG Aerospace Corporation and Wichita State University propose to develop Duocel® metal foams with spatially varying properties and establish simulation and design tools to allow engineers to implement the material. The specific focus on spatially varying properties for this Phase II effort is based on the feedback and interest from the team’s end-user, customer, and commercial organization support obtained during the Phase I effort. Based on ERG’s extensive history with the material, and preliminary acoustic testing using discreet blocks of material, the output of the Phase II is expected to allow adoption into several areas of interest. This proposal ties into the AFRL’s national defense-related mission need in the area of structural materials for air and space systems. Specifically, designing and quantifying the material properties of a lightweight metallic Duocel® structure with spatially varying properties will enable advanced and tailorable designs for structural, acoustic, and fluid flow applications. The technology developed as a result of this effort may become directly adaptable to solving mission needs within AFRL. The main goal of AFRL involvement in this project is to assess the suitability of metallic foam for aerospace applications, including thermal management, and ultimately transition a customizable solution to industrial partners for utilization in future system designs for air and space craft. The mission impact of this project on the Air Force and the Department of Defense will be new, tunable, lightweight structural materials enabling increased capability of future systems for the Air and Space Force. ERG will also work closely with Lockheed Martin who supports the development of this material to meet the growing market need of advanced acoustic materials, and structures with varying properties. Battle Born Supply Company also supports the effort and plans to use the material developed for several areas of interest identified in the proposal.