Why is Duocel aluminum foam so special?

Duocel aluminum foam is a true metal skeletal structure. It is not a sintered, coated, or plated product. Its purity is typi cally that of the parent alloy metal,
with no voids, inclusions, or entrapments.
The matrix of cells and ligaments is completely repeatable, regular, and uniform throughout the entirety of the material. Duocel is a rigid, highly porous and
permeable structure and has a controlled density of metal per unit volume.

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

*these values were derived from small samples where edge effects influenced the results. Larger samples having a minimum of 1 0-15 bubble diameter
produce more general test results which are in better compliance with the equations.

More Information:
Thermal Conductivity:
Aluminum has great thermal conductivity for its cost and weight. Because of the high surface area of Duocel foam, heat trans fer to/from fluids flowing
through the foam is greatly accelerated over solid aluminum and aluminum fins.

Duocel aluminum foam is also ideal for use with phase change materials (PCM) because of the large amount of surface area, wh ich
increases coupling to PCM.
Please visit our thermal conductivity page in the technical data section for a more in depth explanation of how materials and properties effects the thermal
conductivity of Duocel foam.

Crush Strength:
When a load is applied to a foam structure, it will initially yield elastically. However, at approximately 4-6% of strain, depending on the sample size, the foam
structure will begin to buckle and collapse continuously at a relatively constant stress. Depending upon the initial relative density of the foam, this constant
collapse will proceed to approximately 50-70% of strain. At that point, the stress / strain curve will begin to rise as the compressed foam enters the
"densification" phase.

The point in the stress / strain curve where it transitions from the elastic to plastic deformation phase defines the "crush strength" of th e
foam. This is an important mechanical parameter as it is obviously essential to remain below that level for any structure that is being
designed to maintain its shape under design load
Please visit our energy absorption page in the technical data section for a more in depth explanation of how materials and properties effects the crush
strength of Duocel foam.

Electrical Conductivity:
Aluminum is a very good conductor of electricity. This allows Duocel aluminum foam to act as a a grounding medium and as an electrode in electrical
applications

Duocel aluminum foam has also been used to block electromagnetic radiation.

http://www.ergaerospace.com/Aluminum-properties.htm

enormous amount of surface area of the foam.

Please visit our electrical conductivity page in the technical data section for a more in depth explanation of how materials and properties effects the electrical
conductivity of Duocel foam.

Density:
We manufacture our foam from solid aluminum, which already has a low density. The resulting foam is extremely lightweight and is commonly used in weight
sensitive aerospace applications. We have the capacity to reduce the foam to a relative density of 3% to 12%. Higher densities can be achieved thro ugh post
foaming compression.

Duocel aluminum foam also has a high strength-to-weight ratio. It is a great material for lightweight structural applications.
Size:
For our Duocel aluminum foam we are limited to continuous sizes that fit into either 5 x 7 x 18 or 4 x 14 x 16. For pieces any larger we are able to use
multiple pieces and bond or braze them together.

Cost:
Our products can range anywhere from $2.00 to $500.00+ per cubic of foam for a fully machined end item component. Our foams are generally only
economically viable in projects where high performance is more critical than high cost.
ERG does not sell foam as a raw bulk material, only as finished end item components.

Coatings:
Duocel aluminum foam can be anodized, chem filmed, and metal plated just as solid aluminum for increased corrosion resistanc e and/or higher thermal
conductivity.

Corrosion resistance:
Aluminum naturally has a tough oxide layer that helps prevent corrosion. This layer is normally stable from 4.5 to 8.5 pH. Wi thin that pH range, aluminum is
very corrosion resistant.

Aluminum is susceptible to galvanic reaction.

Magnetism:
Though none of our normally foamed materials are magnetic, they can be nickel plated for magnetism.

http://www.ergaerospace.com/Aluminum-properties.htm