Abstract: Disclosed is a structural material using novel, high-purity aluminum, which is produced by using fine aluminum powder as the material, as well as a method for manufacturing such structural material. A processed aluminum material having the properties of an aluminum structural material constituted by aluminum, aluminum carbide and unavoidable impurities except aluminum and aluminum carbide is characterized in that a material obtained by uniformly dispersing stearic acid in fine aluminum powder is filled in an L-shaped bent die, and pressures are applied to the material from one direction and the other direction of the die wherein the pressure applied to the material from the one direction of the die is greater than the pressure applied to the material from the other direction of the die, to cause the material to pass through a hole of the L-shaped bent die so that the material is given and accumulates giant strain, and this process is performed continuously.

Abstract: A process for producing a shaped metallic article includes the steps of melting a metal alloy, reducing the temperature of the molten metal to the liquidus temperature, casting the molten metal at the liquidus temperature into a mould and solidifying the molten metal to obtain a feedstock material. The feedstock material is subsequently heated to a temperature between the liquidus and solidus temperatures to produce a self-supporting thixotropic material which is then formed to the desired shape. Casting the feedstock material from a melt at substantially the liquidus temperature produces a microstructure that is especially suitable for subsequent forming of the thixotropic material and this allows use of slower forming speeds and lower forming pressure during the forming step.

Abstract: A calcined microsphere of ultrafine bauxite particles having a mean particle size in the range 0.01 to 0.3 micrometers, said microsphere having a particle size less than 30 micrometers and being characterized by a substantially solid form having a pycnometric density substantially falling in the range 3.2-3.0 g/cm.sup.3, a BET surface area substantially falling in the range 0.05 to 0.5 m.sup.2 /g and a crystal grain size less than 4 micrometers, the surface chemistry of the microsphere being modified to enhance the wettability of the microsphere and to improve its ability to bond strongly with matrix materials in use.

Abstract: A calcined microsphere of ultrafine bauxite particles having a mean particle size in the range 0.01 to 0.3 micrometers, said microsphere having a particle size less than 30 micrometers and being characterized by a substantially solid form having a pycnometric density substantially falling in the range 3.2-3.9 g/cm.sup.3, a BET surface area substantially falling in the range 0.05 to 0.5 m.sup.2 /g and a crystal grain size less than 4 micrometers, the surface chemistry of the microsphere being modified to enhance the wettability of the microsphere and to improve its ability to bond strongly with matrix materials in use.