CA2064099A1 - Process of manufacturing particle reinforced metal foam and product thereof - Google Patents

Process of manufacturing particle reinforced metal foam and product thereof

Info

Publication number
CA2064099A1
CA2064099A1 CA002064099A CA2064099A CA2064099A1 CA 2064099 A1 CA2064099 A1 CA 2064099A1 CA 002064099 A CA002064099 A CA 002064099A CA 2064099 A CA2064099 A CA 2064099A CA 2064099 A1 CA2064099 A1 CA 2064099A1
Authority
CA
Canada
Prior art keywords
metal
foam
gas
melt
metal foam
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002064099A
Other languages
French (fr)
Inventor
Wolfgang W. Ruch
Bjorn Kirkevag
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Norsk Hydro ASA
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=19892250&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA2064099(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Individual filed Critical Individual
Publication of CA2064099A1 publication Critical patent/CA2064099A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/08Alloys with open or closed pores
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/08Alloys with open or closed pores
    • C22C1/083Foaming process in molten metal other than by powder metallurgy

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Powder Metallurgy (AREA)
  • Laminated Bodies (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

Particle reinforced low cost metal foam is provided by a process of manufacturing metal foam based on foaming of molten composite material using finely dispersed cellulating gas.

Description

WO 91/01387 P~/NO90/i)Olt5 ~t,"' ' 20~099 .,".

A process of manufacturing particle reinforced metal foam and ~roduct thereof The present invention relates to a process of providing metal foam and more particularly to a process resulting in provision of thin wall close cell particle reinforced metal foam.

Foamed metals, as well as foamed ceramics and plastics, due to their unique combination of properties and light weight are earning growing attention as engineering materials.

There are several ways to produce foams. Different foaming tech-niques are known such as incorporating hydrides in the molten metal or a~ding organic compounds which release gases on heat-ing. Vapor deposition on polymeric substrates or casting of metal around granules which are then leached out leaving a porous --'al structure are other examples of providing metals with cel ~lar structure.

The process of foam formation using blowing agents is affected by the surface tension and viscosity of the actual melt. The viscosity counteracts bur~ting of the cell walls during a pro-gressive increase in the volume of the formed bubbles, while a low surface tension will favour formation of thin bubble walls.

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The properties of foams being gas-in-solid dispersions are largely determined by their density, but the cell size, struc-ture and their distribution are also important parameters in-fluencing the properties.

In general such foamed metals are produced by adding a gas evolving compound to the molten metal followed by heating of the resultant mixture to decompose the compound and to produce ex-panding cellulating gases. The foaming compound is usually metal hydride such as TiH2 or ZrH2, and after the foaming step the mould is cooled to form a solid foam material. Cells of non-uniform structure and/or undesirably large size are experienced due to the difficulties with uniform distribution of the evolv-ing gas through the whole volume of the foamed metal.

GB patent No. l.287.994 discloses a process for preparation of metal foams applying a viscosity increasing agent comprising an inert gas or an oxygen containing material gaseous at the melt conditions and treating the thus produced viscous melt with a foaming agent. Air, nitrogen, carbon dioxide, argon and water are preferably used in the process as viscosity increasing agents in amounts from l to 6 grams per lO0 grams of metal alloy. Metal hydrides are used as foaming agents (hafnium, titanium or zirconium hydrides) in amounts of from 0,5 to l,0 grams per lOO grams of alloy.

Preferably the increase in viscosity is enhanced by the presence of a promoter metal, e.g. from 4 to 7 weight% magnesium is used in aluminium alloys. A good mixing technique is required, the addition of foaming agents is usually carried out at a tempera-ture lower than addition of the viscosity increasing agent in a separate second vessel. The disclosed batchwise process, achiev-ing better foams with regard to uniform size and distribution of the cells, and claiming a certain reduction in the consumption of foaming agents, is a rather complicated time consuming and ~' , : . :~.
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WO9l/~1387 PCT/NO~0/00115 2~6~099 , 3 expensi.ve process requiring several process steps and units based on use of expensive heat decomposible gas evolving com-pounds (hydrides).

European patent application No. 0 210 803 discloses a similar batchwise method of producing foamed metals based on use of from 0,2 to 8,0 weight% metallic calcium as viscosity adjusting agent and titanium hydride in amounts of from 1 to 3 weight% of the molten melt as foaming agent.

Still another method of producing cellularized metal by decompo-sition of a heat-decomposable gas evolving compound in molten metal is disclosed in US patent No. 3.297.431. The improvement comprises addition of an intimately dispersed, finely divided powder to the metal prior to decomposition of the gas evolving compound (carbonates or hydrides), or dissolving of gas in the melt. The stabilizing powders may be metals or non-metals, elements or compounds, and two wettable powders are preferen-tially used where one of which forms a solid alloy with the metal. Usually the gas is dissolved at one pressure and then evolved at a second lower pressure.

A drawback in common for the hitherto known processes is that all of them are batchwise operating processes using either ex-pensive gas evolving compounds or dissolved gases as cellulating means and viscosity increasing or stabilizing additives to achieve quality metal foams.

Furthermore, the prior art processes require a close control with the temperature and pressure conditions at different steps of the process. Consequently, so far there is no method operat-ing on an industrial scale in an economical way offering a low cost metal foam to compete with other engineering materials.

WO91/01387 PCT/NO90/00~5 ~.
2 ~ 4 ~

Accordingly, it is an object of this invention to provide a simple low cost method for preparation of quality foams.

Another object of the invention is to provide a method for up-grading of scrap metal material.

Still another object of the invention is to provide a novel type of particle reinforced metal foam having improved mechanical properties.

The invention in its various aspects will be described in details, and various other objects, advantages and additional features thereof will become more apparent from the following description and accompanying patent claims which are to be read in conjunction with the attached drawings, Fig. 1-4, where Fig. 1 shows schematically in the form of a flow-sheet the process of preparation of metal foam accord-ing to the invention, Fig. 2 displays a natural size contact print of the foamed metal sample prepared according to the invention, Fig. 3 shows an optical metallograph picture of the closed cell Al-foam structure, "
Fig. 4 illustrates graphically results from a compres-sion test conducted on foam samples.

Referring to Fig. 1, illustrating schematically the process of metal foam preparation, it has been found that a metal foam of the closed cell type structure having a uniform density and cell structure can be provided simply by feeding of finely dispersed . .

- ,, ~ , ' :' , .. .
.

. . ': ' WO91/013X7 PCT/NO~/nOIl~
' - 5 20~099 cellulating gas into a molten particle reinforced metal matrix composite material (PMMC). No Cpecial additives adjusting the viscosity of the melt or particular precautions with regard to the distribution of the cellulating gas bubbles through the melt were required. The gas bubbles rise to the top of the melt and form foam gradually increasing in volume. No tendency to burst-ing of the foam cells when they reach the melt surface was ob-served. This indicates a (highly) stabilized surface of the gas bubbles. The upper portion of the foam cake solidifies and can be easily removed. Even foam which is not completely solidified can be removed whithout changing the cell structure due to the thick consistency of the formed foam. This is a quite important feature of the method according to the present invention, which allows to run the process continuously by transfer of semi-solidified foam to the moulds. There is even a possibility of subjecting the foam at this stage to certain forming operations, something which dffers a flexibility with regard to the final shape of the resultant metal foam semiproducts.

Example 1 30 kg of an eutectic aluminium alloy (Sil2MglNi2,5) was melted in an open crucible. The molten alloy kept at a temperature of 650C was added silicon carbide particles of an average size of 12/um, and simultaneously CO2 gas was finely dispersed through the melt by means of a special treatment rotor as disclosed in US
patent No. 4.618.427. During the feeding of a CO2 surplus into the formed molten composite material bubbles started to rise to the top of the melt forming a raising foam layer. The upper por-tions of the foam solidified with no sign of surface burst.

Fig. 2 shows in natural size a photographic picture of the resultant foam sample removed as the solidified top part of the foam cake. The cross-section of the sample exhibits a uniform distribution of cells having a diameter in the range of from 1 to 5 mm. The density of the sample was measured to 0,2 g/cm3.

2Q~93 Exam~le 2 20 kg of scrap PMNC material (Al203 reinforced Al-alloy) was re-melted in an open crucible. Pressurized air was applied as source of cellulating gas in this case, finely dispersed and distributed as described in Example 1.

Also in this case the resulting bubbles gave rise to a foamed structure when they reached the top of the melt in the crucible and were allowed to cool.

The achieved pores (cells) are essentially spherical and closed providing the foamed metal with isotropic properties in all directions, especially with regard to energy adsorption.
Metallographic examination of the structure on the samples achieved from Example 1 reveals an extremely thin walled foam stxucture, as illustrated in Fig. 3. The wall thickness in this metallograph picture, magnification of 20, is in order of the reinforcing SiC particle size approximately 12tum.

The mechanical behaviour of the produced foam is represented in Fig. 4 illustrating the results from the testing of compressive stress conducted on the samples from Example 1. The achieved flat stress/strain curve from the samples having an initial height of 26 mm applying a crosshead velocity of 2 mm/min. is typical for this type of material as long as the cell structure did not collapse completely. The energy absorption of this foam was determined to be 2 kJ/l foam, which is a very favourable value compared to the values reported in literature for commer-cially provided Al-foams. Obviously, the achieved improved mechanical properties of the resultant foams are a result of a beneficial influence from the reinforcing particles incoxporated in the cell walls.

Evidently, the above described novel method of preparation of foamed metals according to the present invention offers several . - , . . ~ . ~' ' . .- . - ~

' WO91/01387 PCTtNO90/00115 7 2 ~ 9 9 advantages both with regard to the economics of the process and the characteristics of the resulting foams.

First of all there is an opportunity to run the process con-tinuously by continuous remelting or feeding of molten article reinforced metal material using a variety of available gases as a cellulating gas, e.g. N2, Ar, CO2, He and even pressurized air, which is normally easily available at low costs.

There are no special requirements to temperatures, pressure or uniform distribution of gas bubbles during the foaming and solidification of the resultant foamed metal. The density and to a certain extent also the cell size are simply controlled by dispersion of the cellulating gas through the melt, preferen-tially by applying the above special treatment rotor, but also other means ensuring finely dispersed bubbles can be applied.
The foam accumulated on the top of the melt can be directly fed into moulds for solidification in desired shapes and dimensions or subjected to a certain grade of deformation/reshaping of the semis~lidified foam.

Furthermore, even if it is possible to prepare the molten par-ticle reinforced alloy in a separate process step using an active gas and addition of reinforcing particles prior to apply-ing of the cellulating gas, the biggest potential of the present invention is an up-grading of low grade composite scrap material. This constantly increasing volume of composite scrap today represents a considerable problem since it can not simply be remelted or incorporated to the recycled secondary aluminium.

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Claims (9)

Claims
1. A process of manufacturing particle reinforced metal foam, c h a r a c t e r i z e d i n t h a t the process is a continuous process comprising steps of providing molten composite metal material, feeding of cellulating gas into the melt, foaming of the melt and accumulation of foamed metal on the top of the melt, and finally removal and solidification of the foamed metal.
2. The process according to claim 1, c h a r a c t e r i z e d i n t h a t the molten composite material is provided by re-melting of particle metal matrix composite material.
3. The process according to claim 1, c h a r a c t e r i z e d i n t h a t the composite material is formed in situ in the vessel by adding and distribution of reinforcing particles in the molten metal or alloy by means of an active gas.
4. The process according to claim 3, c h a r a c t e r i z e d i n t h a t the active gas is CO2 gas and the particles are refractory particles.
5. The process according to one or more preceding claims, c h a r a c t e r i z e d i n t h a t the molten composite material is aluminium or aluminium alloy.
6. The process according to claim 1, c h a r a c t e r i z e d i n t h a t the cellulating gas is air.
7. A close cell particle reinforced metal foam characterized by cell wall thickness from 10 to 20µm comprising reinforcing refractory par-ticles.
8. The reinforced metal foam according to claim 7, c h a r a c t e r i z e d i n t h a t the matrix metal is aluminium alloy reinforced by SiC particles.
9. The reinforced metal foam according to claim 8, c h a r a c t e r i z e d i n t h a t the foam exhibits a compressive strength of 0,2 kg/mm2 at a density of 0,2 g/cm3.
CA002064099A 1989-07-17 1990-07-11 Process of manufacturing particle reinforced metal foam and product thereof Abandoned CA2064099A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO892925 1989-07-17
NO892925A NO172697C (en) 1989-07-17 1989-07-17 PROCEDURE FOR THE MANUFACTURING OF PARTICULAR REINFORCED METAL FOAM AND RESULTING PRODUCT

Publications (1)

Publication Number Publication Date
CA2064099A1 true CA2064099A1 (en) 1991-01-18

Family

ID=19892250

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002064099A Abandoned CA2064099A1 (en) 1989-07-17 1990-07-11 Process of manufacturing particle reinforced metal foam and product thereof

Country Status (13)

Country Link
EP (1) EP0483184B1 (en)
JP (1) JP2635817B2 (en)
KR (1) KR100186782B1 (en)
AT (1) ATE100867T1 (en)
BR (1) BR9007549A (en)
CA (1) CA2064099A1 (en)
DE (2) DE69006359T2 (en)
DK (1) DK0483184T3 (en)
ES (1) ES2049037T3 (en)
HU (1) HU210524B (en)
NO (1) NO172697C (en)
RU (1) RU2046151C1 (en)
WO (1) WO1991001387A1 (en)

Families Citing this family (28)

* Cited by examiner, † Cited by third party
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US5112697A (en) * 1989-09-06 1992-05-12 Alcan International Limited Stabilized metal foam body
JP3045773B2 (en) * 1991-05-31 2000-05-29 アルキャン・インターナショナル・リミテッド Method and apparatus for manufacturing molded slab of particle-stabilized foam metal
DE4233695C2 (en) * 1992-10-07 1996-07-11 Wicona Bausysteme Gmbh Composite panel for wall coverings
CA2087791A1 (en) * 1993-01-21 1994-07-22 Martin Thomas Production of particle-stabilized metal foams
DE4318540A1 (en) * 1993-06-04 1994-12-08 Bayerische Motoren Werke Ag Method and device for producing a composite component
DE19501659C1 (en) * 1995-01-20 1996-05-15 Daimler Benz Ag Method for producing component made of metal foam
NO953858D0 (en) * 1995-09-29 1995-09-29 Norsk Hydro As laminate
ES2167938T3 (en) * 1997-08-30 2002-05-16 Honsel Gmbh & Co Kg ALLOY FOR THE MANUFACTURE OF METAL FOAM BODIES BY THE USE OF A DUST WITH GERMAN TRAINING ADDITIVES.
NO981119L (en) 1998-01-14 1999-07-15 Norsk Hydro As Coachbuilding
DE19813176C2 (en) * 1998-03-25 2000-08-24 Fraunhofer Ges Forschung Process for the production of composite parts
WO2000073694A1 (en) 1999-05-26 2000-12-07 Thermotite As Heat-insulated steel pipe for deep-sea pipelines and method for producing the same
RU2193948C2 (en) * 1999-07-06 2002-12-10 Лебедев Виктор Иванович Method for making porous metal and articles of such metal
DE19948830B4 (en) * 1999-10-06 2005-11-24 Terex-Demag Gmbh & Co. Kg Telescopic boom for cranes
US6343640B1 (en) * 2000-01-04 2002-02-05 The University Of Alabama Production of metal/refractory composites by bubbling gas through a melt
NO311708B1 (en) 2000-02-25 2002-01-14 Cymat Corp Process and equipment for forming molded products
US6464933B1 (en) 2000-06-29 2002-10-15 Ford Global Technologies, Inc. Forming metal foam structures
AT410103B (en) * 2001-06-15 2003-02-25 Huette Klein Reichenbach Gmbh METHOD FOR PRODUCING A LIGHTWEIGHT MOLDED BODY AND MOLDED BODY FROM METAL FOAM
US7195662B2 (en) 2001-06-15 2007-03-27 Huette Klein-Reichenbach Gesellschaft Mbh Device and process for producing metal foam
US6660224B2 (en) 2001-08-16 2003-12-09 National Research Council Of Canada Method of making open cell material
MXPA04001490A (en) 2001-08-17 2004-12-06 Cymat Corp Method and apparatus for low pressure aluminum foam casting.
US7108828B2 (en) 2001-08-27 2006-09-19 National Research Council Of Canada Method of making open cell material
WO2003074163A1 (en) 2002-03-04 2003-09-12 Cymat Corp. Sealed impeller for producing metal foam and system and method therefor
US20040126583A1 (en) * 2002-11-19 2004-07-01 Takashi Nakamura Foaming agent for manufacturing a foamed or porous metal
DE102005037069B4 (en) * 2005-08-05 2010-03-18 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Porous composites based on a metal and process for their preparation
JP4189401B2 (en) * 2005-10-05 2008-12-03 本田技研工業株式会社 Method for producing foamed aluminum
DE102008000100B4 (en) 2008-01-18 2013-10-17 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. A process for producing a lightweight green body, then manufactured lightweight green body and method for producing a lightweight molded article
CN111434788B (en) * 2019-01-15 2021-10-19 杨怡虹 Production and preparation method of composite foamed aluminum material
CN110052594B (en) * 2019-04-25 2024-01-02 清华大学 Foam metal preparation method and foam metal preparation device

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FR1259163A (en) * 1960-05-24 1961-04-21 Lor Corp Foaming granulated aluminum
US3297431A (en) * 1965-06-02 1967-01-10 Standard Oil Co Cellarized metal and method of producing same
US3816952A (en) * 1969-02-19 1974-06-18 Ethyl Corp Preparation of metal foams with viscosity increasing gases
FR2282479A1 (en) * 1974-08-19 1976-03-19 Pechiney Aluminium Foamed aluminium alloy - made by casting alloy contg. hydrogen and oxygen and permitting expansion on release of gases

Also Published As

Publication number Publication date
JPH04506835A (en) 1992-11-26
EP0483184A1 (en) 1992-05-06
EP0483184B1 (en) 1994-01-26
WO1991001387A1 (en) 1991-02-07
ATE100867T1 (en) 1994-02-15
JP2635817B2 (en) 1997-07-30
KR920703862A (en) 1992-12-18
NO892925L (en) 1991-01-18
HU9200169D0 (en) 1992-06-29
KR100186782B1 (en) 1999-05-01
ES2049037T3 (en) 1994-04-01
DK0483184T3 (en) 1994-05-30
BR9007549A (en) 1992-06-30
DE483184T1 (en) 1992-08-13
NO892925D0 (en) 1989-07-17
DE69006359T2 (en) 1994-05-11
RU2046151C1 (en) 1995-10-20
HU210524B (en) 1995-04-28
DE69006359D1 (en) 1994-03-10
NO172697C (en) 1993-08-25
NO172697B (en) 1993-05-18
HUT60791A (en) 1992-10-28

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Legal Events

Date Code Title Description
FZDE Discontinued