Scaling up of Composite Metal Foam Manufacturing for HazMat Packaging and Transportation

The large number of tank cars that need to be manufactured, retrofitted or modified each year to meet the safety requirements of DOT-117 specifications demands a large manufacturing capacity for any candidate material, such as Composite Metal Foam (CMF), that is going to be used in their structures. Currently the CMF technology is scaled from lab size production to 1’ x 1’ panels production in small quantities.The objective of this Phase I proposal is to study the design integration; market evaluation; feasibility and cost estimate of setting up a mass production manufacturing line and final cost estimate of Composite Metal Foam panels of 3’ x 3’ that can address the thermal performance and impact resistance requirements for adoption in the structure of tank cars carrying Hazardous Materials (HAZMAT). Ultimately, CMF’s potentials as a light-weight alternative forprotection of tank cars against fire and impact will be demonstrated to tank car builders and the Association of American Railroads (AAR) Tank Car Committee for adoption in the structure of tank cars carrying HAZMAT, improving their safety and fuel economy.