Thermal Response of Steel–Steel Composite Metal Foams under Small‐Scale Torch‐Fire Conditions

Steel–steel composite metal foam (S–S CMF) is a novel metal matrix composite material characterized by its high strength‐to‐weight ratio and unique mechanical and thermal properties. It is made up of hollow stainless‐steel spheres, embedded in stainless steel matrix, with 65–70% air in the structure making it effective as an insulating material. S–S CMF is being explored for use in tank cars carrying hazardous materials (HAZMATs) as a potential partial replacement for conventional carbon steel and thermal insulating material currently being used. In this study, S–S CMF material is numerically and experimentally evaluated for its thermal protection performance. Experimental studies are conducted in scaled‐down jet fire condition while numerical studies are conducted using fire dynamics simulator (FDS). Based on experimental and modeling results, as well as uncertainty studies, 13–15 mm thick S–S CMF ranging in density of about 2.5 g cc⁻¹ tested as novel structural/insulating material meets the acceptance criterion for small‐scale simulated torch‐fire testing. Further success is anticipated in future full‐scale evaluation of 122 × 122 cm samples. The outstanding fire resistance and thermal protection of S–S CMF is attributed to the substantial volume of air trapped within the material, which correlates to its total density.