Metal Foam

New metal foam material absorbs seven to eight times the energy absorbed by similar foams

Uncompressed and Compressed Metal Foam

Aerospace engineering professor Afsaneh Rabiei set out to make a material as light as aluminum and stronger than stainless steel. Her goal was to create something that could be used in products that would save lives, save energy and eventually save money, all at the same time.

Metal Foam Disk

The ultra-high-strength composite metal foam created by Afsaneh Rabiei is a highlight of a well-traveled career during which the researcher has tried to learn everything she can about advanced materials. The result: a brand new sponge-like material made from lightweight aluminum and hollow steel beads that can save energy and lives.

Professor Afsaneh Rabiei, College of Engineering at North Carolina State University

After five years of work - with a group of her students - she has the desired results. Rough traffic accident calculations show that by inserting two pieces of her composite metal foam behind the bumper of a car traveling 28 miles per hour (mph), the impact would feel the same to passengers as the impact if they were traveling at only 5 mph.

Rabiei sees plenty of uses for her invention, including in airplanes, boats, and structures that need impact protection while maintaining low weight. It’s this high strength-to-density ratio — defining a material that’s both strong and light — that makes Rabiei’s foam unique.

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