EP0483184B1 - A process of manufacturing particle reinforced metal foam and product thereof - Google Patents

A process of manufacturing particle reinforced metal foam and product thereof Download PDF

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Publication number
EP0483184B1
EP0483184B1 EP90910522A EP90910522A EP0483184B1 EP 0483184 B1 EP0483184 B1 EP 0483184B1 EP 90910522 A EP90910522 A EP 90910522A EP 90910522 A EP90910522 A EP 90910522A EP 0483184 B1 EP0483184 B1 EP 0483184B1
Authority
EP
European Patent Office
Prior art keywords
metal
foam
gas
process according
molten
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.)
Expired - Lifetime
Application number
EP90910522A
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German (de)
English (en)
French (fr)
Other versions
EP0483184A1 (en
Inventor
Wolfgang Walter 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.)
Cymat Corp
Original Assignee
Norsk Hydro ASA
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Publication date
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Application filed by Norsk Hydro ASA filed Critical Norsk Hydro ASA
Priority to AT90910522T priority Critical patent/ATE100867T1/de
Publication of EP0483184A1 publication Critical patent/EP0483184A1/en
Application granted granted Critical
Publication of EP0483184B1 publication Critical patent/EP0483184B1/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy

Definitions

  • the present invention relates to a process of providing metal foam and more particularly to a process resulting in provision of thin wall closed cell particle reinforced metal foam.
  • foams There are several ways to produce foams. Different foaming techniques are known such as incorporating hydrides in the molten metal or adding organic compounds which release gases on heating. Vapor deposition on polymeric substrates or casting of metal around granules which are then leached out leaving a porous metal structure are other examples of providing metals with cellular structure.
  • the process of foam formation using blowing agents is affected by the surface tension and viscosity of the actual melt.
  • the viscosity counteracts bursting of the cell walls during a progressive increase in the volume of the formed bubbles, while a low surface tension will favour formation of thin bubble walls.
  • foams being gas-in-solid dispersions are largely determined by their density, but the cell size, structure and their distribution are also important parameters influencing the properties.
  • 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 expanding 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 evolving gas through the whole volume of the foamed metal.
  • GB patent No. 1.287.994 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 1 to 6 grams per 100 grams of metal alloy.
  • Metal hydrides are used as foaming agents (hafnium, titanium or zirconium hydrides) in amounts of from 0,5 to 1,0 grams per 100 grams of alloy.
  • 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 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 achieving 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 expensive process requiring several process steps and units based on use of expensive heat decomposible gas evolving compounds (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 decomposition 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 preferentially used where one of which forms a solid alloy with the metal.
  • 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 expensive gas evolving compounds or dissolved gases as cellulating means and viscosity increasing or stabilizing additives to achieve quality metal foams.
  • Another object of the invention is to provide a method for upgrading 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.
  • 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 cellulating gas into a molten particle reinforced metal matrix composite material (PMMC).
  • PMMC metal matrix composite material
  • No special 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 bursting of the foam cells when they reach the melt surface was observed. This indicates a (highly) stabilized surface of the gas bubbles.
  • the upper portion of the foam cake solidifies and can be easily removed.
  • 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.
  • 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 structure, 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 12 ⁇ m.
  • Fig. 4 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 commercially provided Al-foams.
  • the achieved improved mechanical properties of the resultant foams are a result of a beneficial influence from the reinforcing particles incorporated in the cell walls.
  • 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.

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)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Polyurethanes Or Polyureas (AREA)
EP90910522A 1989-07-17 1990-07-11 A process of manufacturing particle reinforced metal foam and product thereof Expired - Lifetime EP0483184B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT90910522T ATE100867T1 (de) 1989-07-17 1990-07-11 Verfahren zur herstellung eines dispersionsverfestigten metallschaumes sowie verfahren zu seiner herstellung.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO892925 1989-07-17
NO892925A NO172697C (no) 1989-07-17 1989-07-17 Fremgangsmaate ved fremstilling av partikkelforsterket metallskum og resulterende produkt

Publications (2)

Publication Number Publication Date
EP0483184A1 EP0483184A1 (en) 1992-05-06
EP0483184B1 true EP0483184B1 (en) 1994-01-26

Family

ID=19892250

Family Applications (1)

Application Number Title Priority Date Filing Date
EP90910522A Expired - Lifetime EP0483184B1 (en) 1989-07-17 1990-07-11 A process of manufacturing particle reinforced metal foam and product thereof

Country Status (13)

Country Link
EP (1) EP0483184B1 (ru)
JP (1) JP2635817B2 (ru)
KR (1) KR100186782B1 (ru)
AT (1) ATE100867T1 (ru)
BR (1) BR9007549A (ru)
CA (1) CA2064099A1 (ru)
DE (2) DE483184T1 (ru)
DK (1) DK0483184T3 (ru)
ES (1) ES2049037T3 (ru)
HU (1) HU210524B (ru)
NO (1) NO172697C (ru)
RU (1) RU2046151C1 (ru)
WO (1) WO1991001387A1 (ru)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0930221A2 (en) 1998-01-14 1999-07-21 Norsk Hydro Asa Vehicle space frame structure
US6343640B1 (en) * 2000-01-04 2002-02-05 The University Of Alabama Production of metal/refractory composites by bubbling gas through a melt
US6464933B1 (en) 2000-06-29 2002-10-15 Ford Global Technologies, Inc. Forming metal foam structures
US6840301B2 (en) 2001-08-17 2005-01-11 Cymat Corp. Method and apparatus for low pressure aluminum foam casting
US6866084B2 (en) 2000-02-25 2005-03-15 Cymat Corporation Method and means for producing moulded foam bodies
US7481964B2 (en) 2002-03-04 2009-01-27 Cymat Corp. Sealed impeller for producing metal foam and system and method therefor
DE102008000100A1 (de) 2008-01-18 2009-07-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Leichtgewichtiger Grün- und Formkörper aus einem keramischen und/oder pulvermetallurgischen Material und Verfahren zu seiner Herstellung

Families Citing this family (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5112697A (en) * 1989-09-06 1992-05-12 Alcan International Limited Stabilized metal foam body
CA2109957C (en) * 1991-05-31 1998-12-15 Harry Sang Process and apparatus for producing shaped slabs of particle stabilized foamed metal
DE4233695C2 (de) * 1992-10-07 1996-07-11 Wicona Bausysteme Gmbh Verbundplatte für Wandbekleidungen
CA2087791A1 (en) * 1993-01-21 1994-07-22 Martin Thomas Production of particle-stabilized metal foams
DE4318540A1 (de) * 1993-06-04 1994-12-08 Bayerische Motoren Werke Ag Verfahren und Vorrichtung zur Herstellung eines Verbundbauteils
DE19501659C1 (de) * 1995-01-20 1996-05-15 Daimler Benz Ag Verfahren zur Herstellung eines Metallschaumteils
NO953858D0 (no) * 1995-09-29 1995-09-29 Norsk Hydro As Laminat
EP1017864B1 (de) * 1997-08-30 2001-11-07 Honsel GmbH & Co. KG Legierung zum herstellen von metallschaumkörpern unter verwendung eines pulvers mit keimbildenden zusätzen
DE19813176C2 (de) * 1998-03-25 2000-08-24 Fraunhofer Ges Forschung Verfahren zur Herstellung von Verbundwerkstoffbauteilen
GB2365942B (en) 1999-05-26 2003-10-15 Thermotite As Heat-insulated steel pipe for deep-sea pipelines and method for producing the same
RU2193948C2 (ru) * 1999-07-06 2002-12-10 Лебедев Виктор Иванович Способ получения пористого металла и изделий из него
DE19948830B4 (de) * 1999-10-06 2005-11-24 Terex-Demag Gmbh & Co. Kg Teleskopausleger für Krane
AT410103B (de) * 2001-06-15 2003-02-25 Huette Klein Reichenbach Gmbh Verfahren zur herstellung eines leichtgewichtigen formkörpers und formkörper aus metallschaum
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
US7108828B2 (en) 2001-08-27 2006-09-19 National Research Council Of Canada Method of making open cell material
US20040126583A1 (en) * 2002-11-19 2004-07-01 Takashi Nakamura Foaming agent for manufacturing a foamed or porous metal
DE102005037069B4 (de) * 2005-08-05 2010-03-18 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Poröse Verbundwerkstoffe auf Basis eines Metalls und Verfahren zu deren Herstellung
JP4189401B2 (ja) * 2005-10-05 2008-12-03 本田技研工業株式会社 発泡アルミニウムの製造方法
CN111434788B (zh) * 2019-01-15 2021-10-19 杨怡虹 一种复合型泡沫铝材的生产制备方法
CN110052594B (zh) * 2019-04-25 2024-01-02 清华大学 泡沫金属制备方法及泡沫金属制备装置

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1259163A (fr) * 1960-05-24 1961-04-21 Lor Corp Moussage de l'aluminium granulé
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 (fr) * 1974-08-19 1976-03-19 Pechiney Aluminium Pieces en alliage d'aluminium poreux et moyen de les preparer

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0930221A2 (en) 1998-01-14 1999-07-21 Norsk Hydro Asa Vehicle space frame structure
US6343640B1 (en) * 2000-01-04 2002-02-05 The University Of Alabama Production of metal/refractory composites by bubbling gas through a melt
US6866084B2 (en) 2000-02-25 2005-03-15 Cymat Corporation Method and means for producing moulded foam bodies
US6464933B1 (en) 2000-06-29 2002-10-15 Ford Global Technologies, Inc. Forming metal foam structures
US6840301B2 (en) 2001-08-17 2005-01-11 Cymat Corp. Method and apparatus for low pressure aluminum foam casting
US7481964B2 (en) 2002-03-04 2009-01-27 Cymat Corp. Sealed impeller for producing metal foam and system and method therefor
DE102008000100A1 (de) 2008-01-18 2009-07-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Leichtgewichtiger Grün- und Formkörper aus einem keramischen und/oder pulvermetallurgischen Material und Verfahren zu seiner Herstellung

Also Published As

Publication number Publication date
BR9007549A (pt) 1992-06-30
KR920703862A (ko) 1992-12-18
KR100186782B1 (ko) 1999-05-01
HU210524B (en) 1995-04-28
WO1991001387A1 (en) 1991-02-07
JPH04506835A (ja) 1992-11-26
NO172697B (no) 1993-05-18
NO892925L (no) 1991-01-18
DE483184T1 (de) 1992-08-13
DE69006359T2 (de) 1994-05-11
CA2064099A1 (en) 1991-01-18
DE69006359D1 (de) 1994-03-10
DK0483184T3 (da) 1994-05-30
EP0483184A1 (en) 1992-05-06
HU9200169D0 (en) 1992-06-29
RU2046151C1 (ru) 1995-10-20
ES2049037T3 (es) 1994-04-01
HUT60791A (en) 1992-10-28
JP2635817B2 (ja) 1997-07-30
ATE100867T1 (de) 1994-02-15
NO172697C (no) 1993-08-25
NO892925D0 (no) 1989-07-17

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