This paper gives an overview over research activities of the Foundry Institute within the DFG priority programme "Cellular Metallic Materials" (SPP1075). Open-cell metallic sponges produced by precision casting feature unique mechanical and physical properties that potentiate their use as a multi-purpose functional material. Their high open porosity of up to 98% has led to first commercial applications as heat exchangers and filters; however, due to their accurately adjustable and uniform pore size they are particularly well suited for light-weight structural components. The production process introduced in the present paper allows the casting of complex near-net-shape components consisting of cellular structures as well as completely dense regions in one single production step. Thus, complex hollow components with imbedded cellular structures for additional stiffness or damping can be produced without the need of additional welding or soldering steps. In order to provide a basis for the use of precision cast sponges in structural applications, investigations on the mechanical properties as well as extensive research on an advancement of the production process have been carried out.
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