Revolutionary NCSU Welding Method Prevents Bubbles in Metal Parts
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Researchers at North Carolina State University have discovered a welding technique for composite metal foam (CMF) that maintains the material’s desirable properties. CMF, a lightweight and strong material made of hollow, metallic spheres embedded in a metallic matrix, has potential uses in a variety of applications including aircraft wings and body armor. The induction welding technique uses an electromagnetic field to heat the metal, allowing a good weld without impairment to the CMF’s properties, and thus presenting a way to join CMF components together.
Composite Metal Foam Welding Technique Unveiled at North Carolina State University
Researchers at North Carolina State University have identified an innovative welding method that enables joining of composite metal foam (CMF) units without affecting the material’s desirable properties. CMFs, characterized by their lightweight, strength, and high-temperature insulation capability, are promising for various applications such as aircraft wings, vehicle armor, and body armor.
CMFs consist of hollow, metallic spheres embedded in a metallic matrix making them excellent for insulating against high heat and holding potential for transporting hazardous and heat-sensitive materials.
Manufacturers’ challenge to utilize CMF’s applications lies in welding multiple CMF components together, a problem due to traditional fusion welding’s inability to maintain the desirable properties of CMFs.
The team has identified induction welding as an effective solution. This technique uses an induction coil to create an electromagnetic field that heats the metal for welding. As CMF is only 30-35% metal, the electromagnetic field penetrates deeply into the material, allowing for a durable weld while preserving the CMF’s properties.
“This is an important step forward, as it’s necessary to have a method of welding the CMF components without affecting the properties that make it attractive,” says Afsaneh Rabiei, a professor of mechanical and aerospace engineering at NC State.
The paper, “A Study on Welding of Porous Metals and Metallic Foams,” is published in the journal Advanced Engineering Materials.
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