Duocel® Aluminum Foam
Applications:
Fluid Flow Control Devices
Energy/Impact Absorption
Compact Heat Exchangers
Lightweight Composite Panels
Trabecular Bone Simulation
Physical Characteristics

 

Properties

Duocel Aluminum Foam is available in a density range of 3-12% uncompressed and can be compressed up to 60% dense relative to the solid base metal. Available standard pore sizes include 5, 10, 20 and 40 pores per linear inch (PPI) and can be adjusted independently or by varying the relative density. Duocel Foam is produced through a proprietary process developed by ERG in which the resulting foam has the identical chemical composition of the base alloy used. Duocel is presently available in aluminum alloys of 6101 and A356 with other alloys available on special order. Foam properties can be tailored for a specific application and material response by adjusting the foam density, pore size, alloy, and ligament structure.

The high specific surface area, low density and open-celled nature of Duocel provide a combination of properties ideally suited for high-tech applications where conventional materials and products are not adequate. While our technical staff would be pleased to discuss these and other applications with you, some common applications of Duocel Aluminum Foam are given below. For specific design issues, contact ERG's staff engineers to discuss your application and how best to use Duocel to make your design the best on the market.

 

Common Applications:

Fluid Flow Control Devices
Gas Diffusers and Mixers - The large surface area of Duocel Aluminum foam promotes uniform gas distribution regardless of flow asymmetry even in low pressure flow regions. A controlled pressure drop and tortuous path through the foam provides the essential micro-turbulent blending for thorough mixing. Several materials are available that can be tailored to the specific system for longer life and reduced maintenance. Aluminum foam used in etching showerheads delivers uniform gas flow and grounds the assembly to prevent plasma arcing. A large surface area to volume ratio allows for a more compact design and improved system efficiency.

Liquid/Gas Separators - The three-dimensional continuous ligament structure of Duocel foam promotes complete removal of entrained liquids. Aluminum foam alone or with standard surface treatments ensures long life and low maintenance. With up to 97% void volume, extremely small pressure drops can be achieved. The continuously connected aluminum structure prevents particle generation from within the liquid/gas separator.
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Energy/Impact Absorption - The stress-strain response of Duocel foam can be tailored for a number of specific application requirements by varying the density and alloy of the foam, while its isotropic properties provide identical response without regard to impact angle. A high strength-to-weight ratio results in superior performance and greater shear strength than honeycomb of the same density. The constant stress portion of the stress-strain curve extends to more than 50% strain, and the foam can be pre-crushed to change the yield point and response as needed.
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Compact Heat Exchangers - As with fluid flow control devices, the high surface area to volume ratio allows for a more compact design than other materials can provide. The ligament structure of Duocel foam promotes complete mixing and efficient scrubbing of the heat exchange surfaces. All aluminum brazed joints provide continuous, highly conductive heat paths and superior overall thermal conductivity, all at less than 10% the weight of solid aluminum.
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Lightweight Composite Panels - With a high specific stiffness, Duocel Aluminum foam provides an excellent strength-to-weight ratio and is light enough for use in ultra-light applications. Foam is highly suitable for step-and-repeat processes as well. Duocel is especially effective for use with optics, where the foam provides high environmental stability and can be used for integral, isothermalizing heat exchangers.
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Trabecular Bone Simulation - Cellular materials are common in nature, with just a few examples being wood, cork, coral and bone. The open-celled, interconnected stucture of Duocel foam mimics that of the cancellous bone material found in our own bodies, especially when made in the same 8-10% density. Duocel foams are used for its biomimicking structure in orthaepedic research and testing applications.

Figure 1: Human Cancellous Bone	Figure 2: Duocel Aluminum Foam

Physical Characteristics of Duocel Aluminum Foam (8% Nominal Density 6101-T6)

Compression Strength	367 psi	(2.53 MPa)
Tensile Strength	180 psi	(1.24 MPa)
Shear Strength	190 psi	(1.31 MPa)
Modulus of Elasticity (Compression)	13.5 × 103 psi	(93.08 MPa)
Modulus of Elasticity (Tension)	11 × 103 psi	(75.84 MPa)
Shear Modulus	2.9 × 104 psi	(199.95 MPa)
Vickers Hardness	35
Specific Heat	.214 BTU/lb·°F	(.895 J/g·°C)
Bulk Thermal Conductivity	3.4 BTU/ft·hr·°F	(5.8 W/m·°C)
Coefficient of Thermal Expansion (0-100°C)	13.1 × 10-7 in/in·°F	(23.58 × 10-6 m/m·°C)
Bulk Resistivity	2.84 × 10-5 ohm · in	(7.2 · 10-5 ohm · cm)
Melting Point	1220°F	(660°C)

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View our online Duocel Aluminum Foam Material brochure.


Other Metals - If aluminum does not meet your design requirements, you may be interested in one of the other metals that we produce. For more information on other materials such as copper or nickel, please contact us.