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Abstract An aluminum foam sandwich (AFS) is a lightweight material that has great potential for applications in the automotive industry. In this work, the production routes of metal foams and metal foam sandwiches are reviewed. We compare the mechanical properties of AFS, such as high mass-specific bending stiffness, compressive strength and crash-absorption capacity, with other materials such as steel, aluminum alloys, or fiber composites and place them in a cost/weight comparison. Additional functional properties such as high electromagnetic damping, increased sound absorption, and improved fire resistance underline its multi-functional character. Furthermore, possible joining techniques and parts of AFS for modern car bodies, such as the battery box, are discussed.
Neu et al. (Wed,) studied this question.
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