Cellular structures 

Lightweight modules with a high degree of structural stability are called for in various sectors, particularly the transportation industry. And, depending upon the application, there are other requirements with reference to vibration dampening, high-temperature and chemical resistance. These sets of requirements can be met with open- or closed-porous composite structures for a variety of material combinations. 

The processes developed at Fraunhofer IFAM for manufacturing cellular metallic structures are especially good for foaming hollow shapes/sections and manufacturing flexurally strong sandwich molding parts. Structures can be toughened with regularly arranged porosity by sintering hollow metallic spheres or metallic foams. 

The Fraunhofer IKTS is launching complementary developments with cellular ceramic materials. They include foam ceramics with porosities up to 90 per cent that can be used for filtering metal melts, as heating elements (SiC) and carriers for catalysts. 

Brake cylinder foamed with aluminum 
(© Fraunhofer IFAM)

Extremely small thermal expansion allows engineers to build large-size sandwich modules  with dense Si/SiC ceramics as the exterior layer with low weight.