Metal foams in modern engineering: A state-of-the-art review on manufacturing techniques, applications, and challenges

Metal foams have recently garnered considerable attention as multifunctional materials due to their low density, high-energy absorption, thermal insulation properties, and favorable strength-to-weight ratio. This review presents recent advancements in metal foam research, emphasizing manufacturing techniques, classification by cell structure and material composition, and their diverse applications. The main fabrication methods are analyzed in terms of process mechanisms, resulting properties, and industrial relevance. The advantages, limitations, and physical constraints of each technique are discussed. Finally, the paper highlights key challenges, including cost, quality control, and scalability, and outlines future trends that focus on sustainable materials, design optimization, and hybrid processing strategies. This review aims to guide researchers and engineers in selecting suitable manufacturing routes and developing innovative applications for advanced metal foams by providing a structured comparison of methods and highlighting pathways for scalable, sustainable production.

کلیدواژه ها:

Metal Foams ، Powder Metallurgy ، Gas injection ، Thermal management ، energy absorption