Powder Metallurgical Process for the Production of Metal Foam

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This patent describes a powder metallurgy process for manufacturing metal foams, specifically using only alloy-inherent components. The method involves mixing a base metal powder (such as aluminum or zinc) with an Al(1-x)Mg(x) metal powder (where x ranges from 10% to 100% magnesium content) as a gas-forming agent, compacting the mixture, heating it above its melting point to form the foam, and cooling it to solidify the structure. The innovation allows the gas-forming agent to also serve as an alloy component, removing the need for foreign additives, and results in stable, fine-structured, microcellular metal foams.

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

• Lightweight structural components in automotive, aerospace, and rail industries for improved energy absorption and weight reduction.
• Crash-absorbing elements in vehicles for enhanced passive safety.
• Sound insulation panels and vibration damping applications in construction and machinery.
• Heat exchangers with highly conductive, lightweight metal foam for electronics or industrial equipment.
• Core material in sandwich constructions and panels for buildings and vehicles.
• Filtration and separation media for chemical, environmental, or biomedical uses.
• Customized shapes and porosities for medical implants (e.g., bone scaffolds).

BenefitsContent extracted from patent full text and abstract with AI.

• No need for foreign gas-forming agents: Avoids contamination and maintains alloy purity.
• Lower process cost and complexity due to elimination of special pressure vessels and external foaming agents.
• Produces metal foams with fine, homogeneous, non-connected (closed-cell) pores, improving mechanical and insulating performance.
• Allows for precise control over foam structure and density by adjusting powder composition and processing parameters.
• Enables use of only alloy-compatible elements, preserving desired material properties.
• Results in stable, reproducible foam that maintains its expanded structure and does not collapse easily.
• Can lower the melting point and improve process efficiency by alloy adjustment.

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Patent Abstract

The powder-metallurgical method according to the invention for producing metal foam, which can only be implemented with alloy-inherent components, comprises at least the steps of mixing a powder made of at least the underlying metal of the metal foam, or the underlying metals of the metal foam, with Al(1-x)Mg(x) having 10 mass percent = x = 100 mass percent as a gas-forming agent in the form of metal powder in a concentration of 4 to 50 mass percent; subsequent compacting of the metal powder mixture, then heating the pressed body at atmospheric pressure to a temperature above the melting point of the metal matrix in order to generate a liquid metal foam, and subsequent cooling of the resulting microcellular metal foam at a temperature below the solidus temperature of the metal matrix.