Amorphous Fe-based metal foam

A foam synthesis method that takes advantage of the viscous high-temperature liquid state of Fe-based bulk glass-forming alloys to produce amorphous steel foam is introduced. Zirconium hydride is utilized as a foaming agent taking advantage of the low hydrogen solubility of these glass-forming alloys. Amorphous foams with porosities up to 65% were produced having homogenous cellular morphologies that exhibit cell-size uniformity. Even though intracellular solid regions as thin as a few micrometers are detected, on a global scale the cellular structure is determined to be incapable of alleviating the foam from the brittle nature of the monolithic glass.