US3177574A - Clad porous metal sheets - Google Patents

Clad porous metal sheets Download PDF

Info

Publication number
US3177574A
US3177574A US143622A US14362261A US3177574A US 3177574 A US3177574 A US 3177574A US 143622 A US143622 A US 143622A US 14362261 A US14362261 A US 14362261A US 3177574 A US3177574 A US 3177574A
Authority
US
United States
Prior art keywords
metal
mold
casting
salt
core
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
US143622A
Inventor
Henry A Kuchek
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.)
Dow Chemical Co
Original Assignee
Dow Chemical Co
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
Application filed by Dow Chemical Co filed Critical Dow Chemical Co
Priority to US143622A priority Critical patent/US3177574A/en
Application granted granted Critical
Publication of US3177574A publication Critical patent/US3177574A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4981—Utilizing transitory attached element or associated separate material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting
    • Y10T29/49991—Combined with rolling

Definitions

  • the end product of the present invention has a thin dense metal exterior surface 2 called a cladding and a porous metal core 3.
  • Core metal 3 is of the nature of a metal sponge and has pores which are interconnected.
  • the article of this invention is particularly useful where a light rigid plate is desirable, and where the article is used for storage of liquids as well as a structural member in an assembly, is. aircraft wings used also to store fuel, but the invention is not thus limited.
  • the article In use for liquid storage, the article is stronger than a plain tank of simailar dimension and capacity, and also shows the advantage of inhibiting or damping rapid motion or surge of the liquid when the article is moved suddenly.
  • Preparation of the article of this invention is begun by casting a suitable metal or metal alloy, preferably aluminum or aluminum alloy containing at least 75 percent aluminum, into a mold filled with a water soluble salt in granular form.
  • suitable sizes of granular salt are those as small as will pass a 100 mesh screen and those as large as will allow sufficient metal to remain to result in a self-supporting article, sometimes as much as an inch in diameter or greater, depending on the size of the mold.
  • the shape of the salt will preferably be equiaxed, oblong or irregularly shaped pieces may be employed.
  • the salt must have a melting temperature higher than the temperature at which the metal or metal alloy is to be cast, must be insoluble in the liquid metal or metal alloy, must not be so strongly or rapidly corrosive in aqueous media toward the metal or metal alloy as to destroy the metal or metal alloy in the time required to leach the salt from the casting, and must not be reducible in aqueous media by the cast metal or metal alloy so as to leave an undesired metal residue in the porous core.
  • Salts usable in the method of this invention are, for example, sodium chloride, potassium chloride, barium chloride, and the like which meet the requirements described above.
  • the salt-filled mold Prior to casting, the salt-filled mold is preheated to a temperature near the melting point of the metal or metal alloy. The molten metal is then poured into the hot salt-filled mold. Preheating the mold ensures a good penetration by the metal of the spaces between the salt grains and is particularly desirable if the salt grains are of a very small size.
  • the metal-salt casting is removed from the mold.
  • the casting is given a shape suitable for the core of the article.
  • Thecastin-g is then heated to a suitable temperature and placedcentrally in a mold so as to form a core.
  • the space between the core and the walls of the mold is the same as the thickness desired for the dense metal cladding prior to rolling.
  • Metal of the same general composition as in the metal-salt casting is cast into the mold so as to fill the space between the casting and the walls of the mold.
  • the mold used in this step is generally of a square or rectangular cross-sectional shape. If another shape is used, rolling will form the article so that the major external surfaces are generally parallel.
  • the soaformed article hereinafter referred to as a billet, is preheated to a temperature suitable for rolling operations. After preheating, the billet is rolled in a rolling mill or some similar device until the billet has acquired the desired dimensions in overall size and dense metal coating thickness. Salt is retained in the core to prevent collapse of the pore walls during rolling.
  • the leaching step essentially completes the process.
  • the resultant article has a porous core having relatively uniform interconnected pores, said core being surrounded by a dense metal cladding which is bonded to the core metal so that a final article of essentially unitary structure is obtained.
  • Example A cylindrical mold having a diameter of 3 inches and a depth of 8 inches was prepared by filling it with sodium chloride granules of an 8-12 mesh size, U.S. sieve series.
  • the sodium chloride containing mold was preheated to about 700 C.
  • An aluminum alloy having the nominal composition of 5 percent silicon, balance aluminum was cast into the mold at a temperature of about 760 C.
  • the metal-salt cylinder was re moved from the mold and cut to a rectangular shape of the dimensions 1 /2 x 3 x 3 /2 inches.
  • a steel rod of A inch diameter was threaded into one end of the casting.
  • the casting with the steel rod attached was heated to about 500 C. and centrally placed in a 2 x 4 x 8 inch book mold.
  • the steel rod was used to support the metalsalt casting in its position in the mold as a core.
  • Aluminum alloy having the nominal composition 5 percent silicon, balance aluminum, was cast at about 760 C. into the book mold so as to completely surround the metal-salt core. After solidification of the composite casting, the steel rod was removed.
  • the billet thus formed for a rolling operation was heated to about 315 C. in an electric furnace. Rolling was accomplished on an 8 inch rolling mill having steam heated rolls using a speed of about feet per minute. The billet was reduced in thickness with about a 10 percent reduction per pass. During the rolling operation, the billet was periodically reheated to about 315 C. The billet was finally reduced to a thickness of about /4 inch. v
  • the dense metal ends were cut from the product of the rolling operation, to expose the salt-filled core, and the salt was leached from the pores with water. It is necessary to expose the core in some manner in order to allow water to reach and dissolve the salt in the leaching operation.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Description

April 13, 1965 H. A. KUCHEK 3,177,574
GLAD POROUS METAL SHEETS Filed 001;- 1961 INVENTOR. Henry A. KuC/nfk *gwmm flTTORNEY United States Patent 3,177,574 CLAD POROUS METAL SHEETS Henry A. Kuchek, Auburn, Mich., assignor to The Dow Chemical Company, Midland, Mich., a corporation of Delaware Filed Oct. 9, 1961, Ser. No. 143,622 2 Claims. (Cl. 29-423) This invention relates to a flat, clad, .porous article of manufacture and a method for producing said article.
The accompanying drawing, forming a part of this specification, is an isometric view partially in section of the final product of this invention.
The end product of the present invention has a thin dense metal exterior surface 2 called a cladding and a porous metal core 3. Core metal 3 is of the nature of a metal sponge and has pores which are interconnected.
The article of this invention is particularly useful where a light rigid plate is desirable, and where the article is used for storage of liquids as well as a structural member in an assembly, is. aircraft wings used also to store fuel, but the invention is not thus limited. In use for liquid storage, the article is stronger than a plain tank of simailar dimension and capacity, and also shows the advantage of inhibiting or damping rapid motion or surge of the liquid when the article is moved suddenly.
Preparation of the article of this invention is begun by casting a suitable metal or metal alloy, preferably aluminum or aluminum alloy containing at least 75 percent aluminum, into a mold filled with a water soluble salt in granular form. Suitable sizes of granular salt are those as small as will pass a 100 mesh screen and those as large as will allow sufficient metal to remain to result in a self-supporting article, sometimes as much as an inch in diameter or greater, depending on the size of the mold. While the shape of the salt will preferably be equiaxed, oblong or irregularly shaped pieces may be employed. The salt must have a melting temperature higher than the temperature at which the metal or metal alloy is to be cast, must be insoluble in the liquid metal or metal alloy, must not be so strongly or rapidly corrosive in aqueous media toward the metal or metal alloy as to destroy the metal or metal alloy in the time required to leach the salt from the casting, and must not be reducible in aqueous media by the cast metal or metal alloy so as to leave an undesired metal residue in the porous core. Salts usable in the method of this invention are, for example, sodium chloride, potassium chloride, barium chloride, and the like which meet the requirements described above.
By proper selection of the salt to be employed in the casting step, keeping in mind the requisite properties described above, the practice of this invention may be extended to any rollable metal or metal alloy, as for example, lead, magnesium, aluminum, tin, copper, and their alloys. 7
Prior to casting, the salt-filled mold is preheated to a temperature near the melting point of the metal or metal alloy. The molten metal is then poured into the hot salt-filled mold. Preheating the mold ensures a good penetration by the metal of the spaces between the salt grains and is particularly desirable if the salt grains are of a very small size.
After solidification the metal-salt casting is removed from the mold. By machining or other means, the casting is given a shape suitable for the core of the article. Thecastin-g is then heated to a suitable temperature and placedcentrally in a mold so as to form a core. The space between the core and the walls of the mold is the same as the thickness desired for the dense metal cladding prior to rolling. Metal of the same general composition as in the metal-salt casting is cast into the mold so as to fill the space between the casting and the walls of the mold. The mold used in this step is generally of a square or rectangular cross-sectional shape. If another shape is used, rolling will form the article so that the major external surfaces are generally parallel.
0n completion of the preparatory steps described above, the soaformed article, hereinafter referred to as a billet, is preheated to a temperature suitable for rolling operations. After preheating, the billet is rolled in a rolling mill or some similar device until the billet has acquired the desired dimensions in overall size and dense metal coating thickness. Salt is retained in the core to prevent collapse of the pore walls during rolling.
Removal of the salt from the core of the article is then accomplished by leaching with water. The leaching step essentially completes the process. The resultant article has a porous core having relatively uniform interconnected pores, said core being surrounded by a dense metal cladding which is bonded to the core metal so that a final article of essentially unitary structure is obtained.
The following example is set forth to illustrate, but not to limit, this invention.
Example A cylindrical mold having a diameter of 3 inches and a depth of 8 inches was prepared by filling it with sodium chloride granules of an 8-12 mesh size, U.S. sieve series. The sodium chloride containing mold was preheated to about 700 C. An aluminum alloy having the nominal composition of 5 percent silicon, balance aluminum was cast into the mold at a temperature of about 760 C.
After. solidification, the metal-salt cylinder was re moved from the mold and cut to a rectangular shape of the dimensions 1 /2 x 3 x 3 /2 inches. A steel rod of A inch diameter was threaded into one end of the casting. The casting with the steel rod attached was heated to about 500 C. and centrally placed in a 2 x 4 x 8 inch book mold. The steel rod was used to support the metalsalt casting in its position in the mold as a core.
Aluminum alloy, having the nominal composition 5 percent silicon, balance aluminum, was cast at about 760 C. into the book mold so as to completely surround the metal-salt core. After solidification of the composite casting, the steel rod was removed.
To prepare the billet thus formed for a rolling operation, it was heated to about 315 C. in an electric furnace. Rolling was accomplished on an 8 inch rolling mill having steam heated rolls using a speed of about feet per minute. The billet was reduced in thickness with about a 10 percent reduction per pass. During the rolling operation, the billet was periodically reheated to about 315 C. The billet was finally reduced to a thickness of about /4 inch. v
The dense metal ends were cut from the product of the rolling operation, to expose the salt-filled core, and the salt was leached from the pores with water. It is necessary to expose the core in some manner in order to allow water to reach and dissolve the salt in the leaching operation.
Examination of the article indicated a good metallurgical bond between the core metal and the dense metal cladding, and good communication between the pores in the core. Each ml. of core volume was found to contain about 65 m1. of pore volume, useful for storage of that volume of inert liquid.
Various modifications may be made in the present invention without departing from the spirit or scope thereof, audit is to be understood that I limit myself only as defined in the appended claims.
Iilaimi v i 1. Themcthod pf produciii'g a generally flat, .reetangular article which comprisesv casting a metalinto a mold,
solidificatiqn; placing said casting aSI-he core in,a; se'c nd mold, casting metal i nto, the; second moldy'sd a slto' su rround the core; subjecting the ar ticle thus formed "toja" rolling process; andlemoyingjthe salt b'y leaching,
filled with water soluble salt granules which have, a meltpoint -abqve ,the lempfatupe at which -the metal 'is" l ar zi'rticle which comprises casting a"me/telQfffthfilags of aluminurn-and aluminum alloys'intjq'a mold filled with V water' Soluble, salt granulels which hgvei meltingpoiiit above the temperature at Whichfthe inetaLjs cast; ramm- :ing the salt metal cqsting from the-mold after solidifica- '7 tion,-p1acing said casting (a; the; corel-iua Second, mold,
casting a metal of ,the class' of aluminum and aluminum V allc'iy s iiito the manam' c ild sofas to' surrciiihdltlie 'cre,
subjecting ,the article :thus formed to a rolling process,
and e'mov ing the salt by leaching.
V, V' R eiereiices Cit egi'b y th e Baikminer,
IT DQSTATES 'PAT NTS FOREIGN 'PATENTS 7 MICHAEL' 'V;'BRlNPISL fiimkzi y-Eiahzirien 1-

Claims (1)

1. THE METHOD OF PRODUCING A GENERALLY FLAT, RECTANGULAR ARTICLE WHICH COMPRISES CASTING A METAL INTO A MOLD FILLED WITH WATER SOLUBLE SALT GRANULES WHICH HAVE A MELTING POINT ABOVE THE TEMPERATURE AT WHICH THE METAL IS CAST, REMOVING THE SALT-METAL CASTING FROM THE MOLD AFTER SOLIDIFICATION, PLACING SAID CASTING AS THE CORE IN A SECOND MOLD, CASTING METAL INTO THE SECOND MOLD SO AS TO SUR-
US143622A 1961-10-09 1961-10-09 Clad porous metal sheets Expired - Lifetime US3177574A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US143622A US3177574A (en) 1961-10-09 1961-10-09 Clad porous metal sheets

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US143622A US3177574A (en) 1961-10-09 1961-10-09 Clad porous metal sheets

Publications (1)

Publication Number Publication Date
US3177574A true US3177574A (en) 1965-04-13

Family

ID=22504866

Family Applications (1)

Application Number Title Priority Date Filing Date
US143622A Expired - Lifetime US3177574A (en) 1961-10-09 1961-10-09 Clad porous metal sheets

Country Status (1)

Country Link
US (1) US3177574A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3367023A (en) * 1964-05-26 1968-02-06 Foerderung Forschung Gmbh Manufacturing of a porous metallic electrode
US4909300A (en) * 1986-10-16 1990-03-20 Nabeya Iron & Tool Works, Ltd. Fluid-permeable article producing method
WO2014166841A1 (en) 2013-04-11 2014-10-16 Sma Solar Technology Ag Pore die casting
WO2015039730A1 (en) * 2013-09-17 2015-03-26 Daimler Ag Cast component having at least one porous metal body formed by a casting core

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR615147A (en) * 1925-09-12 1926-12-30 Metal product for obtaining rolled, molded or other articles, and processes for its manufacture
US1743567A (en) * 1926-07-24 1930-01-14 John M Cole Casting and method of making the same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR615147A (en) * 1925-09-12 1926-12-30 Metal product for obtaining rolled, molded or other articles, and processes for its manufacture
US1743567A (en) * 1926-07-24 1930-01-14 John M Cole Casting and method of making the same

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3367023A (en) * 1964-05-26 1968-02-06 Foerderung Forschung Gmbh Manufacturing of a porous metallic electrode
US4909300A (en) * 1986-10-16 1990-03-20 Nabeya Iron & Tool Works, Ltd. Fluid-permeable article producing method
WO2014166841A1 (en) 2013-04-11 2014-10-16 Sma Solar Technology Ag Pore die casting
DE102013103672A1 (en) 2013-04-11 2014-10-30 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Pore-cast
WO2015039730A1 (en) * 2013-09-17 2015-03-26 Daimler Ag Cast component having at least one porous metal body formed by a casting core
CN105555436A (en) * 2013-09-17 2016-05-04 戴姆勒股份公司 Cast component having at least one porous metal body formed by a casting core
US10300524B2 (en) 2013-09-17 2019-05-28 Daimler Ag Casting component having at least one porous metal body formed by a casting core

Similar Documents

Publication Publication Date Title
DE3033225C2 (en) Method for removing the container material from the hot-pressed compact of powder of metallic and / or non-metallic composition
US3138856A (en) Method of producing clad porous metal articles
DE1758845B2 (en) PROCESS FOR MANUFACTURING PRECISION CASTING FORMS FOR REACTIVE METALS
CN110052613B (en) Aluminum/magnesium/aluminum alloy composite plate and preparation method and application thereof
US3362818A (en) Fabrication of poly porosity microstructures
DE10104338A1 (en) Production of flat, metallic integral foams
US3138857A (en) Method of producing clad porous metal articles
US3177574A (en) Clad porous metal sheets
DE2218455B2 (en) COMPOSED FOAM MADE OF INORGANIC HOLLOW BALLS IN A METAL MATRIX AND A PROCESS AND DEVICE FOR MANUFACTURING SUCH FOAMS
DE1185775B (en) Process for the production of precision casting molds with lost models
DE2327273A1 (en) PROCESS FOR MANUFACTURING BODIES FROM POWDER ENCLOSED IN A GLASS CAPSULE
EP0451467B1 (en) Sintering method using a yielding ceramic mould
US4102689A (en) Magnesia doped alumina core material
US3210166A (en) Cast porous metal
US3275424A (en) Clad porous metal articles
DE673505C (en) Process for the production of compact metal bodies
US4765952A (en) Process for producing tungsten heavy alloy sheet by a loose fill hydrometallurgical process
US3544761A (en) Process of welding aluminum
EP0198290B1 (en) Method of casting aluminium alloys
DE19908952A1 (en) Ceramic moulding material for production of vessels and moulds for melting and casting of e.g. superalloys, titanium and titanium alloys
US3237298A (en) Method of casting clad
DE1920466A1 (en) Process for consolidating workpieces
EP3651921B1 (en) Method for sintering metals and non-oxide ceramics
JPH0440104B2 (en)
US3492119A (en) Filament reinforced metals