A metal foam is a cellular structure consisting of a solid metal, frequently aluminium, containing a large volume fraction of gas-filled pores. The pores can be sealed (closed-cell foam), or they can form an interconnected network (open-cell foam). The defining characteristic of metal foams is a very high porosity: typically 75-95% of the volume consists of void spaces. The strength of foamed metal possesses a power law relationship to its density, a 20% dense material is more than twice as strong as a 10% dense material.
AlMgCu foam blown by an intrinsic gas source
Metal foam is what you get when you add a foaming agent, powdered titanium hydride, to molten aluminum, then let it cool. The result is a very strong substance that is relatively light, with 75-95% empty space. Because of its favorable strength-to-weight ratio, metal foams have been proposed as a construction material for space colonies.
Metallic foams typically retain some physical properties of their base material. Foam made from non-flammable metal will remain non-flammable and the foam is generally recyclable back to its base material. Coefficient of thermal expansion will also remain similar while thermal conductivity will likely be reduced.
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