Lightweight cellular materials known as metal foams are a newly emerging class of engineering materials that are currently being evaluated for a broad range of transportation applications. Fraunhofer has developed a powder metallurgy process for producing ultra-lightweight metal foams from aluminum, steel, and other metals and alloys. Because of their very low mass density, controlled porosity, and closed-cell structure, aluminum foams especially are finding engineering uses as lightweight stiffeners in automobiles; energy absorption in crash management, ballistic protection and mine blast mitigation; vibration damping; and sound/thermal insulation. Aluminum foam structures can be designed to provide multifunctional properties, thus providing a high value/cost ratio.
The objective of these two projects was to identify and evaluate the potential benefit of aluminum metal foams in structural members of locomotives and passenger cars for improvement of crush energy absorption. An additional goal was to identify other potential advantages of using aluminum foams in locomotive and passenger car structures. Potential applications of aluminum foam were identified and assessed, such as reducing equipment weight, strengthening collision posts, enhancing fire resistance, and increasing overall passenger safety and comfort.
The final report for this IDEA project can be found at:
