Why is Duocel® copper foam so special?

Duocel® copper foam is a true metal skeletal structure. It is not a sintered, coated, or plated product. Its purity is typically that of the parent alloy metal, with no voids, inclusions, or entrapments.

The matrix of cells and ligaments is completely repeatable, regular, and uniform throughout the entirety of the material. Duocel® copper foam is a rigid, highly porous and permeable structure and has a controlled density of metal per unit volume.

Physical Characteristics of Duocel® Copper Foam* (8% Nominal Density C10100)

Compression Strength131 psi(0.903 MPa)
Tensile Strength*1000 psi(6.9 MPa)
Shear Strength*190 psi(1.31 MPa)
Modulus of Elasticity (Compression)*107 kpsi(736 MPa)
Modulus of Elasticity (Tension)*14.6 × 103 psi(101.84 MPa)
Shear Modulus40.9 kpsi(282 MPa)
Vickers Pyramid Number35
Specific Heat.092 BTU/lb-°F(.385 J/g-C)
Bulk Thermal Conductivity5.84 BTU/ft-hr-F(10.1 W/m-C)
Coefficient of Thermal Expansion (0-100°C)9.44× 10-6 in/in--F(1.7 × 10-5 m/m--C)
Bulk Resistivity2.56 × 10-5 ohm - in (6.5 × 10-5 ohm - cm)
Melting Point1980°F(1080°C)

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Copper has the highest thermal conductivity of ERG’s metal foams for its cost and weight. Because of the high surface area of Duocel® foam, heat transfer to/from fluids flowing through the foam is quite efficient through solid copper and copper fins.

Duocel® copper foam is also ideal for use with phase change materials (PCM) because of the large amount of surface area, which increases coupling to PCM.

Please visit our thermal conductivity page in the technical data section for a more in depth explanation of how materials and properties effects the thermal conductivity of Duocel® foam.

When a load is applied to a foam structure, it will initially yield elastically. However, at approximately 4-6% of strain, depending on the sample size, the foam structure will begin to buckle and collapse continuously at a relatively constant stress. Depending upon the initial relative density of the foam, this constant collapse will proceed to approximately 50-70% of strain. At that point, the stress / strain curve will begin to rise as the compressed foam enters the “densification” phase.

The point in the stress / strain curve where it transitions from the elastic to plastic deformation phase defines the “crush strength” of the foam. This is an important mechanical parameter as it is obviously essential to remain below that level for any structure that is being designed to maintain its shape under design load

Please visit our energy absorption page in the technical data section for a more in depth explanation of how materials and properties effects the crush strength of Duocel® foam.

Copper is an exceptional conductor of electricity. Copper Duocel® foam can act as a superb grounding medium and electrode in electrical applications.

Duocel® copper foam can also be used to block electromagnetic radiation. This is due to the enormous amount of surface area of the foam.

Please visit our electrical conductivity page in the technical data section for a more in depth explanation of how materials and properties effects the electrical conductivity of Duocel® foam.

We manufacture our foam from solid copper. The resulting foam is extremely lightweight and is commonly used in weight sensitive aerospace applications. We have the capacity to reduce the foam to a relative density of 6% to 12%. Higher densities can be achieved through post foaming compression.

Our production is currently limited to Duocel® copper foam parts that fit into 4″ x 4″ x 1″. Please contact us to discuss availability and custom sizing.

Copper will react with oxygen over time and produce a copper oxide on the surface of the metal. This copper oxide will protect the metal from further corrosion.

Copper is susceptible to galvanic reaction.

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