Method for the Production of Metal Foams

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a new method for producing metal foams in which stabilizing nano- or submicron particles are generated in situ during the foaming process by reacting fluoride salts with the molten metal. The stabilizing particles (such as TiC, AlB2, or TiB2) are produced directly in the metallic matrix, resulting in foams with high porosity, improved mechanical properties, and easier processability compared to the traditional methods that require pre-manufactured stabilizing agents.

Use CasesContent extracted from patent full text and abstract with AI.

• Lightweight structural components for automotive and aerospace industries
• Impact energy absorption and crash structures
• Thermal insulation panels
• Sound and vibration damping parts
• Filtration systems for gases or liquids using open-cell metal foams
• Heat exchangers with enhanced surface area
• Sandwich panels and composite structures for civil engineering

BenefitsContent extracted from patent full text and abstract with AI.

• Enables production of highly porous (≥75%) and lightweight metal foams
• Lowers the amount of expensive stabilizing particles required
• Produces finer, more uniform foam structures with submicron stabilizing particles
• Improves mechanical properties and reduces brittleness of the final foams
• Facilitates easier machining and processing of metal foam blocks
• Offers flexibility in choice of base metal (e.g., aluminum, iron, titanium) and stabilizer type
• Improves scalability and reduces costs compared to traditional techniques that use pre-made reinforcing agents

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Inventors & Applicants

Patent Abstract

In a process to form metal foam incorporating stabilizing particles in the matrix, the stabilizing particles are generated as part of an in-situ reaction of molten reactive liquid and molten metal during the foam formation of the starting material. The stabilizing sub-microscopic or nano-particles are fluoride salts introduced to the molten metal where they are mixed and heated to beyond the mixture melting point.