High strength aluminum honeycomb foam is in demand in the automotive industry

Aluminum foam has unique properties compared to dense state, especially in terms of weight. Generally, foam can be divided into two categories: closed cell and open cell, which provide different characteristics.

The peculiarity of the structure with closed cells is that they are not connected with each other. This type of aluminum foam is suitable for applications that require a high level of sound absorption. It is widely used in many structural parts, especially in areas subject to high attenuation capacitance, such as a car front bumper.

Meanwhile, open cell foam, due to its higher pore connectivity, is used in thermal control applications. One of these is a heat exchanger. Thanks to its porous structure, which provides a large surface area, the heat transfer efficiency is improved.

The production of a combined open-cell and closed-cell foam structure in one component is a complex process due to the different processing methods. Scientists have succeeded in developing high-strength aluminum honeycomb foam by integrating porous and dense structures.

The product has demonstrated functional properties that can be used for applications requiring a combination of heat transfer properties and high strength. This is achieved by using NaCl in combination with solid aluminum foam. It is well known that NaCl has a higher melting point than aluminum. Therefore, when the aluminum melts, the liquid fills the spaces between the NaCl grains. Before melting, NaCl is sieved depending on the desired porous structure.