Foam aluminum is a lightweight composite material made by compacting and heating a mixture of aluminum powder and a foaming agent. It has high porosity that provides benefits like energy absorption, insulation, and lightweight construction. Foam aluminum is used in automotive applications like firewalls and bumpers, in military armor and shipbuilding, and for railroad collision protection. It floats, has high stiffness, absorbs impacts well, and can be easily processed while tailoring its properties.

1. ALUMINUM FOAM

2. WHAT is FOAM ALUMINUM?
Foam Aluminum is a composite of high controlled-cell porosity. It is a sandwich
structure offering energy absorption, lightweight construction, and thermal barrier
insulation for many applications. (The compacting of a powder mixture of metal
and foaming agent to high density and then heating the compacted foam
material to a temperature near the metal melting piont.)

3. APPLICATIONS
APPLIED THROUGHOUT THE WHOLE AUTOMOTIVE IDUSTRY:
• Firewalls
• Kick up panels
• Floor panels
• Energy Absorbing Bumpers
• Door side impact bars
• Front crash rails
• Space frame components
• Roll bars
APPLIED IN MILITARY NEEDS:
• Lightweight armor
• Mine blast containment
• Water-tight doors on ships
APPLIED FOR RAILROADS:
• Locomotive collision posts/cages
• Crush buffer zones
• Side impact barriers (passenger cars)

4. BRIEF DESCRIPTION
Advantages
Floats in Water
High Specific Stiffness
Mechanical Damping
Sound Insulator
Excellent Energy Absorption
Non-Flammable
(Easily processed by sawing,
drilling, and milling, and can
be joined by adhesive
bonding, brazing, and TIG
and laser welding techniques.)
Disadvantages
Electrical and Thermal
conductivities of aluminum foam
are reduced, but still in the
typical range of metallic
materials.
Strength and properties can be
Tailored by adjusting:
- Specific weight
- Alloy composition
- Heat treatment
- Morphology of pores