Abstract: A composite porous media for either gas or liquid flow is strong and efficient, and can readily be formed in or into a wide range of different shapes and configurations. In particular, the porous media is a composite of a metal, aerogel or ceramic foam (i.e., a reticulated inter-cellular structure in which the interior cells are interconnected to provide a multiplicity of pores passing through the volume of the structure, the walls of the cells themselves being substantially continuous and non-porous, and the volume of the cells relative to that of the material forming the cell walls being such that the overall density of the intercellular structure is less than about 30 percent theoretical density) the through pores of which are impregnated with a sintered powder or aerogel. The thickness, density, porosity and porous characteristics of the final composite porous media can be varied to conform with what is demanded by the intended use.

Abstract: A composite porous media for either gas or liquid flow is strong and efficient, and can readily be formed in or into a wide range of different shapes and configurations. In particular, the porous media is a composite of a metal, aerogel or ceramic foam (i.e., a reticulated inter-cellular structure in which the interior cells are interconnected to provide a multiplicity of pores passing through the volume of the structure, the walls of the cells themselves being substantially continuous and non-porous, and the volume of the cells relative to that of the material forming the cell walls being such that the overall density of the intercellular structure is less than about 30 percent theoretical density) the through pores of which are impregnated with a sintered powder or aerogel. The thickness, density, porosity and porous characteristics of the final composite porous media can be varied to conform with what is demanded by the intended use.

Abstract: A composite porous media for either gas or liquid flow is strong and efficient, and can readily be formed in or into a wide range of different shapes and configurations. In particular, the porous media is a composite of a metal, aerogel or ceramic foam (i.e., a reticulated inter-cellular structure in which the interior cells are interconnected to provide a multiplicity of pores passing through the volume of the structure, the walls of the cells themselves being substantially continuous and non-porous, and the volume of the cells relative to that of the material forming the cell walls being such that the overall density of the intercellular structure is less than about 30 percent theoretical density) the through pores of which are impregnated with a sintered powder or aerogel. The thickness, density, porosity and porous characteristics of the final composite porous media can be varied to conform with what is demanded by the intended use.

Abstract: A composite porous media for either gas or liquid flow is strong and efficient, and can readily be formed in or into a wide range of different shapes and configurations. In particular, the porous media is a composite of a metal, aerogel or ceramic foam (i.e., a reticulated inter-cellular structure in which the interior cells are interconnected to provide a multiplicity of pores passing through the volume of the structure, the walls of the cells themselves being substantially continuous and non-porous, and the volume of the cells relative to that of the material forming the cell walls being such that the overall density of the intercellular structure is less than about 30 percent theoretical density) the through pores of which are impregnated with a sintered powder or aerogel. The thickness, density, porosity and porous characteristics of the final composite porous media can be varied to conform with what is demanded by the intended use.

Abstract: A self-brazing material 10 for use in a heat exchanger 50 using a corrosive heat exchanger fluid is manufactured by providing a first substrate layer 10 and a second layer 12 metallurgically bonding the two layers together to form a composite material 22. This second layer 12 is made of a material chosen from a group consisting of materials capable of having good high temperature and corrosive properties, and melting at a temperature well below that of the first material 10. The bonded material 22 is then reacted so as to render the second layer 12 a brazing layer for the first substitute layer 10 with excellent high temperature and corrosive properties.

Abstract: A metal foil substrate material 50 for catalytic converters 54 and method of making the material in which layers (10, 12, 14) of ferritic stainless steel and aluminum are solid state metallurgically bonded together forming a composite material 24. Such composite material 24 is further rolled to the final foil gauge with no heat treatment and then subjected to a thermal in situ reaction to form a resulting uniform solid solution foil material 50 with superior high temperature corrosion resistance.

Abstract: A high strength titanium alloy or titanium aluminide metal foil having improved strength and density is produced, preferably in coilable strip form, by plasma-depositing the selected titanium-based material on a receiving surface, separating the deposited material from the receiving surface to provide two metal foil preforms each having a relatively smooth side as cast against the receiving surface and a relatively rough, opposite side as deposited from the plasma, disposing the two metal preforms together with the relatively rough sides of the two metal preforms in facing engagement with each other, and squeezing the two preforms together between pressure bonding rolls to metallurgically bond the preforms to each other and to consolidate the materials of the preforms to form a fully dense metal foil.

Abstract: A metal foil substrate material for catalytic converters and method of making the material in which layers of ferritic stainless steel and aluminum are solid state metallurgically bonded together forming a composite material. Such composite material is further rolled to the final foil gauge with no heat treatment and then subjected to a thermal in situ reaction to form a resulting uniform solid solution foil material with superior high temperature corrosion resistance.

Abstract: A metal foil substrate material for catalytic converters and method of making the material in which layers of ferritic stainless steel and aluminum are solid state metallurgically bonded together forming a composite material. Such composite material is further rolled to the final foil gauge with no heat treatment and then subjected to a thermal in situ reaction to form a resulting uniform solid solution foil material with superior high temperature corrosion resistance.

Abstract: Discrete powder particles of copper 14 and INVAR 12 are mixed together in a container 16 and packed into a powder metal article. This article is hot vacuum degassed and vacuum sealed and then heated to temperature well below the sintering temperature of copper or INVAR. Immediately after heating the article, it is subjected to a high pressure, high strain force such as extrusion through a die thereby yielding a fully dense, strong composite material 10 with excellent combined thermal expansion and conductivity properties.

Abstract: Layers of copper and Invar are cold pressure rolled with reduction in thickness to be metallurgically bonded together in interleaved relation, and strips of the bonded materials are cold pressure rolled together a plurality of times with reduction in thickness to be metallurgically bonded together to form a metal composite and to break up the layers of Invar in the composite, thereby to distribute portions of the Invar material in a copper matrix to limit thermal expansion of the composite while permitting the matrix to extend in continuous phase along three mutually perpendicular axes through the composite substantially free of diffusion between the copper and Invar materials.