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ERG has amassed a great deal of engineering mastery over the past 40 years, expertise in both designing and manufacturing DuocelŪ foam metal components. Our engineers can design and optimize DuocelŪ foam components for performance and manufacturability in a broad variety of applications.

For example, we have detailed thermal models for predicting and optimizing the performance of DuocelŪ metal foam heat exchangers. We have mechanical properties test data that can be used to calculate and predict the performance of DuocelŪ foams for impact absorption and structural applications. If you contact us, our engineers can quickly determine if DuocelŪ foam components would be viable in your particular application

Bonding / Brazing

It is possible to bond DuocelŪ products utilizing conventional epoxies and adhesives. Such bonding agents must be compatible to the DuocelŪ base material and its finished operating environment. Bonding is considered a cost effective alternative to brazing.

Brazing is common among our thermal management products to increase their heat transfer efficiency. Specialized brazing techniques and processes are necessary to ensure the highest quality in our products.

Heat Treating

Duocel® metal foams are available in many heat treatable conditions that are derived from the parent material alloy.  ERG Aerospace’s general practice is to provide Duocel® in a T6 or equivalent condition to maximize the strength and durability of the ligaments.

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Our dedicated Duocel® foam metal machine shop covers over 20,000 sq. ft., and is comprised of both manual and CNC machines. Precision machinery coupled with decades of experience by our machinists assures the highest quality Duocel® components and assemblies. Our experience and knowledge in machining open-celled metal foams is unmatched by anyone in the world. We also maintain the unique ability to have our engineering staff co-located in the same building allowing our engineers the flexibility to ensure the Duocel® components meet your required performance criteria.

DuocelŪ foams are unique materials which require special proprietary fabrication and manufacturing processes that ERG Aerospace corporation has developed over the last 40 years. We work with our customers to define the performance requirements and optimize the DuocelŪ component design. We then perform the fabrication and machining to ensure the product meets your quality and performance requirements. ERG's basic and QA systems are based on and certified to AS9100 Rev C, which is the US aerospace version of the international standard ISO 9001. For this reason, we do not sell DuocelŪ foams in raw or bulk form, but only as finished end item components. This ultimately saves everyone time and money, and results in a superior cost-effective product.

Special coating

Plating / Chemical Films

Duocel® foam metals are capable of taking on additional plating or chemical film. Plating is used to increase the primary foam’s corrosion resistance, surface finish, thermal transfer properties, and electrical conductivity. Common metal plating includes nickel, gold, silver and platinum. Plating also reduces the cost of having to manufacture the primary foam in an expensive alloy.

Chemical film coatings and anodized foam are also utilized when additional environmental protection is desired such as in space flight applications.


There are many Non-Destructive Testing (NDT) and Destructive Testing (DT) methods that can be employed to quantitatively characterize the Duocel® foam materials.  Some of these tests include airflow, stress/strain, corrosion, X-ray, filtering, salt and leak testing.