SBIR Phase I: Low-Cost Metal Foams Produced by Novel Manufacturing Technique

这项小型企业创新研究（SBIR）的第一阶段将开发一种制造低成本泡沫铝材料的新方法，这种材料将具有高能量吸收能力、高强度重量比和高刚度重量比。在汽车、船舶和航空航天工业中使用的多孔金属泡沫已经引起了人们的极大兴趣。大多数生产金属泡沫的方法都非常昂贵，而且不容易大规模生产。市售泡沫材料有时难以加工或连接，因为泡沫过程所需的金属基体中存在研磨陶瓷颗粒。这种新颖的发泡工艺将能够使用低成本的制造方法生产各种尺寸和密度的闭孔泡沫铝板或棒形式。与目前最先进的发泡方法相比，泡沫铝将以更低的成本生产。泡沫铝可用于汽车和航空航天应用，需要高强度和刚度重量比。这项技术的广泛影响将是一种比目前的发泡工艺更通用、更经济、更可定制的铝发泡技术。传统的机械加工和焊接技术可用于成形和连接泡沫铝。泡沫技术也将适用于其他金属系统，如铜和镁。由于材料的高强度和刚度重量比，发泡工艺将在航空航天，建筑，船舶和汽车工业中开辟广泛的技术应用。轻质泡沫铝将通过吸收汽车和飞机的能量，提高燃油效率和耐撞性。泡沫铝材料应表现出较高的吸声能力和结构各向同性比蜂窝铝板。轻质泡沫铝可用于标识和面板的建筑应用-单独使用或夹在复合板中。与传统的粉末冶金技术相比，提出的制造方法应以20-40%的成本生产泡沫铝。

This Small Business Innovation Research (SBIR) Phase I will develop a novel method to fabricate low-cost foamed aluminum materials that will exhibit high-energy absorption capability, high strength-to-weight and stiffness-to-weight ratios. There has been a significant interest in porous metal foams for use in the automotive, marine, and aerospace industries. Most methods of producing the metal foams are quite expensive and cannot be easily scaled up to mass production. Commercially available foamed materials are sometimes difficult to machine or to join because of the presence of abrasive ceramic particles within the metal matrix required for the foaming process. This novel foaming process will be capable of producing closed-cell foamed aluminum panel or rod forms in various cell sizes and densities using a low-cost manufacturing approach. The foamed aluminum will be produced at lower cost in comparison to current state-of-the-art foaming methods. The foamed aluminum can be used in automotive and aerospace applications requiring high strength and stiffness to weight ratios.The broader impact from this technology would be an aluminum foaming technology that could be more versatile, economical, and tailorable than current foaming processes. Conventional machining and welding techniques can be used to shape and join the foamed aluminum. The foaming technology will also be applicable to other metal systems, such as copper and magnesium. The foaming process will open a wide range of technological applications within the aerospace, architectural, marine, and automotive industries, due to the material's high strength and stiffness to weight ratio. Lightweight foamed aluminum will enable high fuel efficiencies and improved crashworthiness through energy absorption in automobiles and aircraft. The foamed aluminum material should exhibit high sound-absorption capabilities and be more structurally isotropic than honeycomb aluminum panels. Lightweight foamed aluminum can be used in architectural applications for signs and panels- by itself or in sandwiched composite panels. The proposed fabrication approach should produce foamed aluminum at 20-40% less cost in comparison to conventional powder metallurgy techniques.