ADVANCED MATERIALS & PROCESSES | NOVEMBER/DECEMBER 2025 7 delivering electricity in a flash, like a bolt of lightning, while simultaneously introducing chlorine gas. This approach selectively vaporizes iron and other toxic metals, leaving behind the aluminum. The process is significantly faster than traditional methods, which often require prolonged heating in furnaces or the use of corrosive chemicals. The new method requires no water or solvents and removes sodium salts along the way. Researchers say this technique could benefit industries dealing with other high-volume waste streams such as steel manufacturing, mining, and rare earth processing. rice.edu. SUPER RESILIENT COMPOSITE METAL FOAM A new study at North Carolina State University (NSCU), Raleigh, shows that composite metal foam (CMF) is extremely resilient and able to withstand repeated heavy loads even at temperatures of 400°C and 600°C. Along with the material’s high strength-to-weight ratio, the results suggest that CMF could be used in applications from automobile engines to aerospace components to nuclear power technologies. CMFs are foams that consist of hollow spheres embedded in a metallic matrix. The resulting material is both lightweight and remarkably strong at absorbing compressive forces. In addition, CMF is better at insulating against high heat than conventional metals and alloys such as steel. To learn how CMF would perform under repeated stress at high temperatures, the scientists worked with NC State’s Constructed Facilities Laboratory. For this study, the team worked with CMFs consisting of steel spheres in a steel matrix. Samples were subjected to a repeated loading cycle while exposed to temperatures of 23°C, 400°C, and 600°C. At 400°C, the CMF withstood a loading cycle that alternated between 6 and 60 MPa for more than 1.3 million cycles without failure before the test was halted due to time constraints. At 600°C, the CMF withstood cyclical loading that alternated between 4.6 and 46 MPa for more than 1.2 million cycles without failure before the test was halted. ncsu.edu. Professor Afsaneh Rabiei invented the composite metal foams described here and is working with a small business on its commercialization. Courtesy of NCSU. One Part Supreme 10HT for STRUCTURAL TOUGHENED EPOXY BONDING Hackensack, NJ 07601 USA • +1.201.343.8983 • main masterbond.com www.masterbond.com HIGH BOND STRENGTH Lap shear strength | 3,600-3,800 psi Tensile modulus | 450,000-500,000 psi NASA LOW OUTGASSING Per ASTM E595 standards SERVICE TEMPERATURE RANGE From 4K to +400°F asminternational.axomo.com Show Your ASM Pride! Shop ASM apparel and essentials, a liate society t-shirts, and more in our gear store!
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