by Researchers at North Carolina State University have made a breakthrough in the welding of composite metal foam (CMF) components. The team has identified a welding technique that allows for the joining of CMF without compromising its lightweight, strong, and insulating properties. CMF consists of hollow metallic spheres embedded in a metallic matrix, resulting in a material that is both light and remarkably robust. This unique combination of properties has led to a range of potential applications, from aircraft wings to vehicle armor.
One of the challenges in utilizing CMF for various applications is the need to weld multiple CMF components together. Traditional fusion welding techniques, which involve the melting of metal to fuse two pieces together, have proven problematic for CMF. The solid metal filler used in fusion welding lacks the desirable properties of CMF, and the direct heat used in this process can fill in the porosity of CMF, impairing its properties. Consequently, alternative welding methods are required.
The researchers at NC State University have discovered that induction welding is an effective technique for welding CMF components. Induction welding involves the use of an electromagnetic field created by an induction coil to heat the metal for welding. Since CMF consists of only 30% to 35% metal, the electromagnetic field can penetrate deeply into the material without compromising its properties. The remaining 65% to 70% of CMF, which consists of air pockets, acts as insulation, preventing the heat from spreading beyond the welding site. This unique characteristic of CMF allows induction welding to join two pieces of CMF without impairing its desirable properties.
This breakthrough is critical because CMF has the potential for a wide range of applications, particularly in the storage and transportation of nuclear material, hazardous substances, explosives, and other heat-sensitive materials. The lightweight and strong nature of CMF, coupled with its exceptional thermal insulation capabilities, make it an ideal material for these purposes. However, the ability to weld CMF components together was a significant hurdle that needed to be overcome.
With the identification of induction welding as an effective technique for joining CMF components, manufacturers can now explore and utilize the full potential of CMF in various applications. The preservation of CMF’s properties during the welding process ensures that the material retains its lightweight, strength, and insulating capabilities, making it an attractive choice for use in industries such as aerospace, defense, and hazardous material handling.
This breakthrough research opens up new possibilities for the practical use of CMF, bringing us one step closer to harnessing the full potential of this innovative material. The ability to weld CMF components without impairing its properties will undoubtedly pave the way for advancements in various industries, enabling the development of lighter, stronger, and more efficient products.
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1. Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it
