Development of Steel Foam Materials and Structures
In the past few years there has been a growing interest in lightweight metal foams. Demands for weight reduction, improved fuel efficiency, and increased passenger safety in automobiles now has manufacturers seriously considering the use of metal foams, in contrast to a few years ago, when the same materials would have been ruled out for technical or economical reasons. The objective of this program was to advance the development and use of steel foam materials, by demonstrating the advantages of these novel lightweight materials in selected generic applications. Progress was made in defining materials and process parameters; characterization of physical and mechanical properties; and fabrication and testing of generic steel foam-filled shapes with compositions from 2.5 wt.% to 0.7 wt.% carbon. A means of producing steel foam shapes with uniform long range porosity levels of 50 to 60 percent was demonstrated and verified with NDE methods. Steel foam integrated beams, cylinders and plates were mechanically tested and demonstrated advantages in bend stiffness, bend resistance, and crush energy absorption. Methods of joining by welding, adhesive bonding, and mechanical fastening were investigated. It is important to keep in mind that steel foam is a conventional material in an unconventional form. A substantial amount of physical and mechanical properties are presented throughout the report and in a properties database at the end of the report to support designer's in applying steel foam in unconventional ways.
- Research Organization:
- American Iron and Steel Institute, Fraunhofer, USA (US)
- Sponsoring Organization:
- USDOE Office of Industrial Technologies (OIT) (EE-20) (US)
- DOE Contract Number:
- FC36-97ID13554
- OSTI ID:
- 840932
- Resource Relation:
- Other Information: PBD: 20 Oct 2004
- Country of Publication:
- United States
- Language:
- English
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