Aluminum Foam with Sandwich Structure
Waterproof: The board structure is tight and has good waterproof performance.
Sound insulation: The porous structure of the EPS core can effectively absorb sound waves.
Energy saving: The thermal insulation performance helps to reduce building energy consumption and achieve energy saving goals.
Economical and practical: The cost is relatively low, the cost-effectiveness is high, and it is suitable for large-scale applications, such as industrial plants, warehouses, cold storage, temporary buildings, etc.
Product Introduction
Product Specifications
Panel effective width | Roof:950/960mm |
Wall:950/1150mm | |
Steel sheet thickness | 0.40~0.70mm |
Panel thickness | 50/75/100/150/200mm |
EPS density | 12-14kg/m³ |
Color | As per RAL or customized |
Coating | PE,SMP,HDP,PVDF |
Steel type | PPGL,PPGI steel/Aluminum sheet/Stainless steel sheet |
Length limitaion | Max 5.9m for 20FT |
Max 11.9m for 40FT | |
Joint way | Hidden screws type |
Fire proof | B1/B2 |
Advantage | Waterproof |
Resistances of heat-transfer process | 0.035-0.05w/m·k |
Quality Assurance
Our company has established a top - notch material testing center laboratory, furnished with upwards of 30 pieces of professional equipment. This laboratory serves two main purposes. First, it conducts comprehensive tests on the physical, mechanical, and combustion properties of raw materials, auxiliary materials, and finished products within the enclosure system. Second, it actively participates in the R&D of new products. Moreover, every operation in the laboratory adheres strictly to international - standard operating procedures, ensuring that all the work carried out delivers high - quality and reliable results.
Aluminum foam with sandwich structure is an advanced composite material increasingly used in aerospace, automotive, construction, and defense industries due to its excellent combination of light weight, high strength, and energy absorption capabilities. This article offers a thorough, technical, and SEO-optimized overview of aluminum foam sandwich structures, detailing material composition, manufacturing principles, relevant industry standards, applications, and practical considerations. The content also addresses common questions and provides actionable guidance for engineers and procurement specialists.
What Is Aluminum Foam with Sandwich Structure?
An Aluminum Foam Sandwich Structure consists of two solid metal face sheets bonded to a lightweight aluminum foam core. The foam core is a porous, cellular aluminum material that dramatically reduces weight while providing high stiffness and impact resistance. This design mimics natural structures like bones, optimizing the strength-to-weight ratio.
Material Composition and Manufacturing Process
1. Core Material: Aluminum Foam
Type: Closed-cell aluminum foam
Manufacturing: Techniques include powder metallurgy, casting with gas injection, or infiltration methods.
Density: Typically ranges from 0.2 to 0.8 g/cm³
Porosity: 70%–90% depending on processing
2. Face Sheets
Material: Usually aluminum alloys (e.g., AA5000, AA6000 series), sometimes stainless steel or composites for specialized applications.
Thickness: Varies; typically 0.5–3 mm depending on application.
3. Bonding Techniques
Adhesive bonding: High-strength structural adhesives applied under pressure and temperature.
Diffusion bonding: Metallic bonding achieved at elevated temperature and pressure without melting.
Mechanical fastening: Riveting or bolting, used in repair or hybrid designs.
Engineering Principles and Mechanical Properties
The sandwich structure leverages the bending stiffness principle:
Face sheets carry most tensile and compressive stresses during bending.
Foam core maintains panel shape by resisting shear forces and preventing face sheet buckling.
Typical Mechanical Properties
| Property | Typical Range |
|---|---|
| Density | 0.2 – 0.8 g/cm³ (foam core) |
| Compressive Strength | 3 – 15 MPa (foam core) |
| Shear Strength | 1 – 4 MPa (foam core) |
| Bending Stiffness | 3–10 times higher than solid aluminum panels (depending on thickness) |
| Energy Absorption | Up to 50 kJ/kg |
Key Benefits of Aluminum Foam Sandwich Structures
Lightweight: Significant weight savings up to 70–80% compared to solid metals.
High Specific Strength: Excellent strength-to-weight ratio for structural applications.
Energy Absorption: Ideal for crashworthiness and vibration damping.
Thermal Insulation: Cellular structure offers reduced thermal conductivity.
Corrosion Resistance: Aluminum base provides inherent resistance, further enhanced with coatings.
Design Flexibility: Can be tailored in thickness, density, and face sheet materials.
Industry Standards and Regulations
| Standard / Specification | Application |
|---|---|
| ASTM B923 | Standard specification for aluminum foam products |
| ISO 21920-1 | Aluminum and aluminum alloys - Structural applications - Part 1: General principles |
| MIL-HDBK-5J | Metallic materials and elements for aerospace applications |
| EN 45545 | Fire protection on railway vehicles (applicable coatings/flammability) |
| RoHS Directive | Restriction of hazardous substances compliance |
Applications of Aluminum Foam Sandwich Structures
| Industry | Typical Applications |
|---|---|
| Aerospace | Lightweight panels, interior components, energy absorbers |
| Automotive | Crash protection, floor panels, noise damping |
| Construction | Facade cladding, fireproof doors, thermal insulation |
| Defense | Armor panels, blast mitigation components |
| Marine | Lightweight bulkheads, vibration damping |
Installation and Handling Considerations
Cutting: Use diamond-coated blades or water-jet cutting to minimize deformation.
Machining: Maintain low feed rates to prevent core damage.
Joining: Avoid welding face sheets directly; prefer mechanical fastening or adhesive bonding.
Storage: Store in dry conditions; avoid prolonged exposure to harsh chemicals.
Safety: Aluminum dust generated during machining is combustible; ensure proper ventilation.
Common Questions (FAQs)
Q1: How does aluminum foam sandwich structure compare to honeycomb panels?
A: Aluminum foam offers superior energy absorption and isotropic mechanical properties, while honeycomb provides higher stiffness-to-weight ratios but less impact resistance.
Q2: Are aluminum foam sandwich panels recyclable?
A: Yes, both the foam core and face sheets are recyclable aluminum alloys. Recycling processes separate materials for reuse.
Q3: What are typical thickness ranges for these panels?
A: Total thickness typically ranges from 10mm to 100mm depending on application and load requirements.
Q4: Can these panels be used in fire-critical environments?
A: Yes, aluminum foam has excellent fire resistance, but face sheets and adhesives must meet fire safety standards like EN 45545 or equivalent.
Q5: What testing is required before structural use?
A: Panels undergo mechanical tests (compression, bending, shear), thermal conductivity, fire resistance, and fatigue tests per ASTM and ISO standards.
Conclusion
Aluminum foam with sandwich structure represents a cutting-edge solution for lightweight, high-strength, and energy-absorbing applications across various industries. Its unique combination of properties meets the increasing demands for sustainable and high-performance materials. When designed and manufactured according to recognized standards, these panels deliver superior mechanical performance, thermal insulation, and safety.
Professional Call to Action
Seeking durable, lightweight aluminum foam sandwich panels for your next project?
✅ Customizable core densities and face sheet alloys
✅ Compliance with ASTM, ISO, and MIL specifications
✅ Technical support for design, testing, and installation
✅ Competitive pricing and global delivery
📩 Contact our materials experts today to request detailed datasheets, sample panels, and personalized quotations.
