Breakthrough in Metal Foam Filtration Performance Drives Multi-Domain Application Innovations

1. Filtration Mechanism of Metal Foam: Dual Advantages of Structure and Performance

The filtration capability of metal foam stems from its three-dimensional interconnected pore channels and surface tension effects, integrating both "physical sieving" and "selective permeability" characteristics:  

Multi-level pore design: Pore sizes ranging from micrometers to millimeters enable customizable porosity (60%-98%), allowing for the precise capture of particles of varying sizes (e.g., 86% filtration efficiency with 1.5 mm pores).  

Enhanced capillary effect: When external pressure is lower than the liquid’s surface tension, only low-viscosity fluids (e.g., gases) can pass through, effectively blocking contaminants (e.g., solid particles in diesel engine exhaust).  

Anti-clogging and self-cleaning: The open-cell structure combined with high mechanical strength ensures durability under high-speed fluid impacts (e.g., long-term stability of sand-control screens in sandy fluids).  

2. Industrialization Case Studies: From Lab to Real-World Applications

(1) Diesel Engine Exhaust Purification: High-Efficiency Particle Capture  

Technical breakthrough: A metal foam filtration device designed by Gong Weijia’s team achieved an 86% capture efficiency for diesel engine particulates under conditions of a 150 cm³ cross-sectional area and a 10 cm thickness, while withstanding high temperatures (>300°C) and heavy-load operation.  

Commercial progress: Piloted in collaboration with a heavy machinery manufacturer, it reduces particulate emissions by over 50%, complying with China’s non-road mobile machinery National VI emission standards.  

(2) Sand Control in Oil-Gas Extraction: Erosion Resistance and Long-Term Filtration  

Innovative product: Xing Hongxian’s metal foam sand-control screen, optimized for pore channel tortuosity, achieves >95% sand interception rate and 30% higher flow capacity compared to traditional screens.  

Economic benefits: In Bohai Oilfield trials, the device’s lifespan extended to 3 years (vs. 1.5 years for conventional screens), reducing annual maintenance costs per well by ¥400,000.  

(3) Industrial Dust Removal: Cost-Effective, High-Performance Solution

Case highlight: Shi Jinyun’s team developed a metal foam dust collector with a gradient pore size design (0.5mm surface layer/2mm base layer), achieving 92% dust capture efficiency and 25% lower pressure drop.  

Market feedback: Deployed in cement plant kiln flue gas treatment, the device costs 35% less than ceramic filters and operates for 50,000 hours.  

Metal foam exhibits outstanding advantages in corrosion resistance, noise absorption, damping, energy absorption, high surface area, and porosity, promising broad application potential. Future trends indicate expanded use in automotive, military, aerospace, and construction sectors, alongside interdisciplinary research breakthroughs. These advancements will significantly accelerate the commercialization and industrialization of metal foam composites, fostering cross-domain innovations and sustainable industrial transformation.