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  • Aluminum foam is a relatively new material and its full range of engineering applications is not yet known.  One reason for this is that its material properties have yet to be described in such a way that enables mathematical modeling of the material under different loading conditions.  Once aluminum foam is accurately characterized in terms of Young’s modulus, yield strength, and plateau stress, as well as cell morphology and cell defects, finite element analysis should be able to accurately predict how the material will behave in various applications.
  • Aluminium foam is a highly porous cellular material were pores represent 65 - 90 % of the total volume. Aluminum foam is not used to its greatest advantage when a straight material for material swap is made but when a part or a group of parts is redesigned to optimize the multifuctionality of aluminum foam.


  • Aluminum foam is manufactured using a few different methods.  The foam which will be tested in this study, trade named Alporas, is made by first mixing calcium into the molten aluminum to increase viscosity, then introducing TiH­­ which separates into titanium and hydrogen.  The titanium mixes with the aluminum alloy and the hydrogen causes foaming of the molten mixture which is responsible for creating the porous aluminum foam
  • A first group of foam making processes starts from the molten metal which is processed to a porous material by foaming it directly, by using an indirect method via a polymer foam or by casting the liquid metal around solid filler materials which reserve space for the pores or which remain in the foam.


  • Cymat’s Low Pressure Casting is similar to the aluminum die-casting process, which is commonly used to make aluminum wheels. Cymat’s process involves injecting SAF into a mould. The pressure of injection is controlled so that it is sufficient to fill the mold precisely, while not being so high as to collapse the unique cell structure of SAF. This technology is currently in the developmental phase.
  • Precursor technology involves adding a foaming agent to molten MMC, followed by rapidly cooling the melt to form a solid precursor with a defined shape. Under specific re-heating conditions the precursor will expand to fill a cavity. The result is a uniform-celled foam. A new application for aluminium powders in structural shapes involves the production of lightweight foam panels or components.


  • Metal foams could find use in catalysts, the market for which in the year 2000 approached $27 billion in the United States alone. They could also find use in advanced chemical sensors for explosives and other harmful agents, Tappan said, in storing hydrogen fuel, or even as coatings for pellets in nuclear fusion experiments.
  • A companies aluminum foam found its first commercial application two years ago when a European automaker started putting it in the side frames of its sports cars to help in absorbing the energy from a side collision, Trendelenburg said. There have been a bunch of companies out there trying to make metal foam successful, but no none has been been able to do it cheaper. This company is getting very close to doing it.

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