Lightweight Metal Foam Makes Autos Safer

Almost half a million dollars invested by the National Science Foundation over the last 5 years has just yielded a space age material so light and strong that it makes a 28 mile per hour crash feel like a gentle fender blip at 5 mph.

Afsaneh Rabiei has invented a metal foam with such a high strength-to-density ratio that it could revolutionize the auto industry. She says it isn’t the first metal foam, but hers has tested out as the strongest, partly because it utilizes a metallic matrix to support the cell walls.

Existing metal foams have varying sized cells—tiny pockets of space inside the material. Instead Rabiei made the cells of standard sizes. That (and the metallic matrix) help the foam absorb energy much better than current metal foams.

“This material showed a much higher strength-to-density ratio than any metal foam that has ever been reported,” said Rabiei, associate professor of mechanical and aerospace engineering at North Carolina State University, and the recipient of $452,250 in funding for this purpose since 2003 from the National Science Foundation.

She wanted to use her funding to develop a light, strong material needed to improve safety and fuel economy in the automotive, aerospace and other industries. It looks like she succeeded. The National Science Foundation has picked another winner.

Who says government shouldn’t try to pick winners and losers.

Photo Credit: National Science Foundation

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About Susan Kraemer

Susan Kraemer writes at CleanTechnica, Earthtechling, and GreenProphet and has been published at Ecoseed, NRDC OnEarth, MatterNetwork, Celsius, EnergyNow and Scientific American.

As a former serial entrepreneur in product design she brings an innovator's perspective on inventing a carbon-constrained civilization: If necessity is the mother of invention: solving climate change is the mother of all necessities! As a lover of history and sci fi, she enjoys chronicling the strange future we are creating in these interesting times. 

Follow Susan @dotcommodity on twitter.

  • Lud

    Which process are you using to produce homogenious porosity… There are many processes (that i recall) that can make uniform cell structure like by using space holder materia, hollow spheres, invest casting… etc… The foam that is shown in the picture seems to have drainage so I am a bit curious…

  • Lud

    Which process are you using to produce homogenious porosity… There are many processes (that i recall) that can make uniform cell structure like by using space holder materia, hollow spheres, invest casting… etc… The foam that is shown in the picture seems to have drainage so I am a bit curious…

  • Lud

    Which process are you using to produce homogenious porosity… There are many processes (that i recall) that can make uniform cell structure like by using space holder materia, hollow spheres, invest casting… etc… The foam that is shown in the picture seems to have drainage so I am a bit curious…

  • Interested observer

    So, is there anyone making it now? Is it still in the lab?

  • Interested observer

    So, is there anyone making it now? Is it still in the lab?

  • Interested observer

    So, is there anyone making it now? Is it still in the lab?

  • WhiteStar 160

    How easy is it to form into a specific shape? Can it be injected into a mold?

  • WhiteStar 160

    How easy is it to form into a specific shape? Can it be injected into a mold?

  • http://dotcommodity.blogspot.com Susan Kraemer

    True, it will make it easier to build carbon compliant aeroplanes, which have to become more carbon friendly to even be allowed to land in Europe soon, per their new legislation: They must be 20% more fuel efficent IIRC:

    http://blog.wired.com/cars/2008/04/post.html

  • http://dotcommodity.blogspot.com Susan Kraemer

    True, it will make it easier to build carbon compliant aeroplanes, which have to become more carbon friendly to even be allowed to land in Europe soon, per their new legislation: They must be 20% more fuel efficent IIRC:

    http://blog.wired.com/cars/2008/04/post.html

  • http://dotcommodity.blogspot.com Susan Kraemer

    True, it will make it easier to build carbon compliant aeroplanes, which have to become more carbon friendly to even be allowed to land in Europe soon, per their new legislation: They must be 20% more fuel efficent IIRC:

    http://blog.wired.com/cars/2008/04/post.html

  • http://uk-tv-guide.com TV Guide

    I love this kind of tech because it affects all manner of things.

  • http://uk-tv-guide.com TV Guide

    I love this kind of tech because it affects all manner of things.

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