What is a Flame Arrestor?
A flame arrestor is a passive safety device that prevents a flame front from propagating from one volume into another.
When a flame encounters a properly designed porous structure, heat is rapidly transferred from the combustion gases into the material. If enough heat is removed, the flame temperature drops below the combustion threshold and propagation stops.
Duocel® metal foam accomplishes this through:
- Extremely high internal surface area
- Complex tortuous flow paths
- Controlled pore size
- Excellent thermal conductivity
- Lightweight structural integrity
The result is a compact flame arrestor capable of venting gases while stopping flame transmission.
Why use a Duocel® flame arrestor?
Duocel flame arrestors and breather plugs prevent flame propagation while safely venting pressure and gases.
Our flame arrestors are lightweight, high-performance solutions designed for aerospace, defense, marine, battery, and industrial applications. By combining exceptional surface area with controlled flow characteristics, Duocel® arrests flame fronts while allowing pressure equalization and gas venting.
Flight proven on commercial and military platforms.
What makes a Duocel® flame arrestor superior to traditional designs?
Duocel® foam creates thousands of interconnected pathways that maximize contact between the flame front and the metal structure, rapidly extracting heat from combustion gases.
Controlled Pressure Drop
Every application has unique flow requirements.
ERG can tailor:
- Porosity (PPI)
- Compression
- Thickness
- Material selection
to achieve the required balance between:
- Pressure equalization
- Gas venting
- Flame suppression
while minimizing system pressure losses.
Lightweight Construction
Unlike many traditional flame arrestor technologies, Duocel® provides exceptional performance at very low weight, making it ideal for aerospace and mobile systems.
Structural Integration
Duocel® foam can be:
- Bonded into threaded housings
- Integrated into vent assemblies
- Incorporated into breather plugs
- Manufactured in custom geometries
for rapid system integration.
Typical Applications
Battery Enclosures
Lithium battery systems may require pressure venting while preventing flame propagation during thermal runaway events.
Duocel® flame arrestors allow gases to escape while helping contain flame transmission.
Aircraft Electronics Boxes
Many aerospace electronics enclosures require:
- Pressure equalization
- Environmental protection
- Flame containment
Duocel® flame arrestors can function as both breather plugs and flame arrestors within the same assembly.
Missile and Defense Systems
The lightweight nature of Duocel® metal foam makes it attractive for mission-critical defense applications where safety and mass reduction are equally important.
Marine Systems
Marine compartments often require venting while maintaining protection against flame propagation between volumes. Duocel® foam offers a durable and corrosion-resistant solution.
Vent and Breather Plug Assemblies
Custom threaded and integrated vent designs can combine:
- Pressure equalization
- Gas venting
- Flame suppression
in a single compact component.
Engineering Design Capabilities
ERG can customize flame arrestor performance through:
| Parameter | Adjustable |
|---|---|
| Foam Material | Aluminum, Copper, Carbon, Ceramic, Specialty Metals |
| Porosity (PPI) | Yes |
| Compression | Yes |
| Thickness | Yes |
| Shape | Yes |
| Housing Integration | Yes |
| Pressure Drop Target | Yes |
This allows optimization for both airflow requirements and flame arresting performance.
Why Aerospace Engineers Choose ERG
Flight-Proven Technology
Duocel® flame arrestors are used on multiple aerospace platforms including:
- Boeing 777X
- Lockheed C-130
- Commercial aviation systems
- Missile platforms
providing proven performance in demanding environments.
Decades of Metal Foam Expertise
ERG has manufactured advanced open-cell foams since 1967 and supports applications across aerospace, defense, thermal management, filtration, and energy absorption.
Made in the USA
Design, engineering, manufacturing, and testing are performed in the United States under AS9100 aerospace quality standards.
Frequently Asked Questions
How does a metal foam flame arrestor stop a flame?
The metal foam absorbs heat from the flame front through its extensive internal surface area. When enough heat is removed, combustion can no longer sustain itself and the flame is extinguished.
Can Duocel® be customized for a specific pressure drop?
Yes. ERG can tailor foam characteristics including pore size, compression, thickness, and geometry to meet system flow requirements.
What industries use Duocel® flame arrestors?
Applications include aerospace, defense, marine, electronics protection, battery systems, and industrial venting systems.
Can the flame arrestor be supplied in a housing?
Yes. Duocel® foam can be integrated into threaded housings, breather plugs, and custom assemblies for simplified installation.
Key Advantages
- Stops flame propagation
- Maintains airflow
- Relieves excess pressure to enhance safety
- Meets precise pressure-drop targets
- Seamlessly integrates into a wide range of system architectures
- Proven performance in commercial and military flight applications
Duocel® Benefits
- High surface area in a compact design
- Fine pore structure with controllable compression characteristics
- Exceptional strength-to-weight ratio
- Tunable ligament architecture for optimized mechanical performance
- Durable, lightweight solution for aerospace and high-performance systems
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