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The ultra-high-strength composite metal foam created by Afsaneh Rabiei is a highlight of a well-traveled career during which the researcher has tried to learn everything she can about advanced materials. The result: a brand new material that can save energy and lives. “Basically, it is a new material for all sorts of safety devices,” said Rabiei, associate professor of mechanical and aerospace engineering at North Carolina State University. Rabiei’s invention isn’t the first metal foam, but she says it’s the strongest. The main weakness of existing metal foams is the varying sizes of their cells — tiny pockets of space inside the material. Instead, Rabiei used cells of standard sizes and combined them with a metallic matrix to support the cell walls. That helps

And since the bulk steel is three times heavier than the steel foam, it’s easy to see how the foam could attract car manufacturers looking for a bumper that will improve safety and gas mileage. Rabiei sees plenty of uses for her invention, including in airplanes, boats, and structures that need impact protection with maintaining low weight. It’s this high strength-to-density ratio — defining a material that’s both strong and light — that makes Rabiei’s foam unique. “This material showed a much higher strength-to-density ratio than any metal foam that has ever been reported,” she said.