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The application of foam aluminum in the field of engineering


Foam metal materials possess the characteristics of both metal materials and porous materials, making them a new type of integrated structural functional material with a series of excellent properties such as high porosity, low density, light weight, high strength, and good compressibility. Depending on the matrix, foam metal can be divided into porous foam aluminum, porous foam nickel, porous foam cast iron, and porous foam aluminum alloy. Among them, foam aluminum material is currently the most promising foam metal and is widely recognized as the “metal star”. It has emerged as an outstanding representative of new integrated structural functional materials and is considered a cutting-edge area of focus in material development.

Nickel Foam (6)

Due to its unique porous structure, foam aluminum exhibits excellent physical properties, particularly in terms of mechanical, acoustic, thermal, and electromagnetic shielding performance. These various superior properties of foam aluminum make it a commonly used material in industries such as automotive equipment, aerospace, construction, and environmental protection. It is often employed as a damping and sound-absorbing material, electromagnetic wave shielding material, flame retardant and heat exchange material, as well as a filtering material. As a result, foam aluminum has a highly promising future in terms of its applications.

The automotive industry

Foam aluminum is mainly used in three categories for lightweighting automobiles: foam aluminum castings, foam aluminum sandwich structures, and foam aluminum filling structures. The utilization of foam aluminum materials and sandwich-type composite foam aluminum materials in the construction of lightweight rigid automobile structures, such as truck covers and sliding roof panels, can effectively reduce weight and enhance specific stiffness. Foam aluminum can also be used to manufacture pillars, longitudinal beams, door beams, bumpers, and other components in the vehicle body structure, providing a combination of lightweight and robustness. Approximately 20% of the automobile structure can be constructed using foam aluminum plates. In comparison to steel components, foam aluminum offers the benefits of low cost, good performance, and light weight.

Roll Type Ultra-Thin Foam Copper (7)

Based on various requirements and characteristics, applications of foam aluminum in the automotive industry can be categorized as following types.

– One of the key applications is energy absorption and collision safety. Foam aluminum has the ability to absorb a significant amount of energy under constant force, making it particularly suitable for enhancing the safety performance of automotive collisions. Additionally, as a plastic material, foam aluminum does not experience rebound during deformation, preventing the accumulation and sudden release of energy that could cause further harm.

– Another important application is lightweight structures. Foam aluminum possesses characteristics such as low density, high specific stiffness, and high specific strength, which meet the requirements for stiffness and strength of automotive components while also reducing the overall weight of the vehicle.

– Foam aluminum is also utilized for vibration damping and noise reduction. The porous structure of foam aluminum allows it to absorb and reflect noise, as well as absorb and dissipate vibrational energy. Its application in areas such as engine suspension mounts in automobiles not only improves the structural rigidity and stability but also helps in reducing vibrations and noise.

– Additionally, foam aluminum is used for insulation, heat dissipation, and flame resistance. Due to its poor thermal conductivity, foam aluminum is employed as an insulation material, providing insulation, heat dissipation, and flame-retardant effects in various automotive applications.

Copper Foam, What Is The Application Prospect Of This New Material-2

The aerospace industry

The aerospace industry has always demanded lightweight and high-strength aircraft designs. While aluminum honeycomb structures have a long history of application in aerospace vehicles, their complex manufacturing process and high cost have been a drawback. As an alternative to aluminum honeycomb structures, foam aluminum offers characteristics such as lightweight, high specific strength, excellent damping properties, and low production costs. These properties make foam aluminum an ideal functional and structural material for aerospace engineering, with a wide range of potential applications. Currently, foam aluminum is primarily used in cushioning protective structures, environmental control systems, and thermal control systems of manned spacecraft. Foam aluminum sandwich structures are used to manufacture buffers, shock absorbers, and the bottom of spacecraft return capsules, enabling soft landings and protecting astronauts and space equipment. By effectively absorbing energy and providing shock attenuation, foam aluminum also ensures the safety of astronauts and spacecraft under extreme instantaneous impact loads. In conclusion, foam aluminum has tremendous potential in aerospace applications and is increasingly gaining attention from scientists.

The construction industry

Many architectural facilities require lightweight, high-strength, and flame-retardant structural materials. Due to its physical properties such as lightweight, high temperature resistance, and non-flammability, foam aluminum material can be used as an alternative to many current building materials. The insulation and flame-retardant characteristics of foam aluminum can effectively prevent fires, making it suitable for use in fireproof doors and fireproof partitions. Foam aluminum material is also used for interior ceiling and partition wall decoration, providing not only a lightweight and aesthetically pleasing solution but also offering fire resistance, sound insulation, noise reduction, and thermal insulation effects. To reinforce various types of wall sockets, foam aluminum material can be used to fill the gaps, resulting in a solid and strong structure. In public places such as stadiums, swimming pools, concert halls, conference halls, entertainment halls, and transportation terminals, the use of foam aluminum material for decoration can effectively avoid sound resonance and echo. Additionally, when applied in elevator cabins, foam aluminum can reduce power consumption and provide sound insulation and noise reduction. In conclusion, foam aluminum is widely used in the construction industry due to its sound absorption, insulation, flame retardancy, and lightweight properties.

Picture of Lu


Our materials research team from Tsinghua University postdoctoral researcher lin and Harbin Institute of Technology researcher Mu, Nanjing University of Technology researcher Wei, they share their expertise in foam metal materials article.

About HGP

WE were established in 2003, located in the Gaoxin Zone of Guangdong-Guangxi Cooperation Special Experimental Zone, covering an area of 70 mu, with a plant of about 30,000 square meters, with more than 170 employees, is an advanced new material technology enterprise integrating research and development, production and sales.

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