Skip to main content

Lightweight metal foam components for the transport industry

Objective



In transport industry there is a strong demand for lower
operating costs, higher payloads, improved environmental
compatibility as well as increased passenger safety and
comfort. There are many possibilities to comply with
these sometimes contradictory objectives by lightweight
engineering which can be divided into two main routes: to
utilize lighter and stiffer materials or to establish
better weight saving designs. Aiming for these targets,
metallic foams have been identified as a new class of
material of great interest due to their unique
combination of properties derived from their cellular
structure and metallic behaviour. Recently, two new
processes for the production of metallic foams have been
introduced, both processes having a high potential to
meet the transport industry's demands.

In order to exploit this potential, the overall
objectives of this project are to:
optimize the production processes for aluminium foam,
focused on identified applications in an iterative manner
provide a data base of metallic foam properties and to
contribute to the establishment of design guidelines
develop a modelling tool for computer simulation of
acoustic and mechanical (e.g. crash) behaviour of
metallic foams
assess/demonstrate the competitiveness of aluminium
foam in these applications with regard to technical
performance, cost efficiency and environmental aspects
for the transport industry
investigate processes for the production of Ti based
foam (special applications in aeronautics).

With a successful project resulting in the introduction
of metallic foams in transport industry it is expected
that also SME's manufacturing components also for other
industrial sectors will benefit from this project.

The consortium brings together two process developers for
metallic foams with different production approaches
(Hydro Aluminium and FhG IFAM) and representatives of the
transport sectors railway (ABB), automotive (CR Fiat),
aeronautics (Aerospatiale, Daimler Benz), helicopters
(Eurocopter) and elevator systems (UTE) that define the
requirements of end users. The department for machine
acoustics and machine elements of TH Darmstadt will
contribute their experience in modelling in cooperation
with the industrial partners. The chances for the
transfer of results and quick implementation into
products are excellent due to the good balance between
material producers, end users and institutes.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Fraunhofer-Gesellschaft zur Förderungder Angewandten Forschung e.V.
Address
Lesumer Heerstraùe
28717 Bremen
Germany

Participants (9)

ABB Daimler Benz Transportation Ltd.
United Kingdom
Address
Litchurch Lane
DE24 8AD Derby
CENTRO RICERCHE FIAT S.C.P.A
Italy
Address
50,Strada Torino, 50
10043 Orbassano
EUROPEAN AERONAUTICS DEFENSE AND SPACE COMPANY EADS GIE
France
Address
Boulevard De Montmorency 37
75781 Paris
Eurocopter Deutschland GmbH
Germany
Address

81663 München
Hydro Aluminium AS
Norway
Address

6601 Sunndalsora
Technische Hochschule Darmstadt
Germany
Address
4,Magdalenstraße 4
64288 Darmstadt
Union Tecnologica Espana SL
Spain
Address
165,Paseo De La Castellana 165
28046 Madrid
United Technologies Research Center GmbH.
Germany
Address
Technologiezentrum Am Europlatz
52068 Aachen
Universiteit Stuttgart
Germany
Address
7,Pfaffenwaldring 7
70569 Stuttgart