Aluminium foam–polymer composites: processing and characteristics

Dissemination of closed cell metal foam unique properties (low density, efficient energy absorption, high vibration/sound attenuation) in real life products has often been difficult to realise. With advanced pore morphology (APM) aluminium foam–polymer hybrids a new and simplified process route targeted at application in foam-filled structures (e.g. automotive A-pillar) has been introduced. APM foams are made from spherical, small volume foam elements joined to each other in a separate process step. Joining the aluminium foam elements by adhesive bonding delivers composite foam with approximately 80–95 wt.% aluminium foam and 5–20 wt.% adhesive (polymer). Setting up cellular structures from spherical foam elements allows for automatic part production, good pore morphology control and cost effective aluminium foam application. An automated production line is displayed and discussed. Mechanical properties of APM aluminium foam–polymer hybrids are similar to other closed cell aluminium foams. Integration of APM foams in profiles resulted in significantly improved properties as observed for conventional closed cell aluminium foam fillings. The unique properties of APM composite foams make them an attractive alternative as a cost effective and easily applicable material of construction with targeted uses such as energy absorbing reinforcement of composite structures.