Polymer infused composite metal foam as a potential aircraft leading edge material

The leading edge of aircraft wings must be free from three-dimensional disturbances caused by insect adhesion, ice accretion, and particle wear in order to improve flight performance, safety, and fuel efficiency of the aircraft. An innovative solution was explored in this work by infusing stainless steel composite metal foam (S-S CMF) with a hydrophobic epoxy resin system. S-S CMF was made with 100% stainless steel using a powder metallurgy technique. The infused epoxy filled the macro- and microporosities, unique to S-S CMF's structure, creating a product with a density similar to that of aluminum. The contact angle, wear rate, erosion resistance, and insect adhesion of the novel infused composite metal foam were measured and compared to aluminum, epoxy and stainless steel. The infusion process was determined to fill up to 88% of the pores within the S-S CMF and was found to reduce wettability and insect residue accretion. The contact angle of the infused S-S CMF was 43% higher than its parent material, stainless steel, and 130% higher than aluminum. Insect residue maximum height and areal coverage were reduced by 60 and 30%, respectively, compared to aluminum. Grit blast experiments to simulate erosion resulted in a greater roughness increase for aluminum than for the parent epoxy resin or the resin-infused S-S CMF. These results suggest that the durability and performance of infused S-S CMF was superior compared to aluminum, which is the current leading edge material of choice. Based on the promising results under relevant wear and erosion conditions, it is concluded that the infused S-S CMF can offer a potential tailored replacement to aluminum leading edge material.