Abstract: Composite products and methods of making the same are provided.

Abstract: A spool has a spirally-wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web. The channel is oriented with the pair of arms parallel to the axis of the spool and with the central web extending radially, relative to the axis of the spool. The channel has a plurality of adjacent windings, a first and second of the arms of spirally-wound channel cumulatively forming the inner and outer surfaces of the spool. The arms are spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is received between the arms of adjacent windings and is retained therein to establish an overlap of windings in the axial direction. Other embodiments feature S, B and E-shaped channels to form the spool, some embodiments having inner and outer layers of channel.

Abstract: Various illustrative embodiments of a free-machining aluminum alloy composition and related methods are provided. The aluminum alloy composition can include an aluminum alloy and an effective amount of a graphitic material as a free-machining constituent. Free-machining means the graphitic material is capable of modifying the machining character of the aluminum alloy by affecting the generation of chip-shaped machining debris and/or the friction between the machining tool and the workpiece.

Abstract: Various illustrative embodiments of an apparatus and method for reducing the dissolved hydrogen content of a molten metal alloy are provided. The disclosed embodiments can be utilized for the processing of molten metal alloys such as aluminum, and more particularly, for the removal of dissolved hydrogen from molten metal alloys such as aluminum. Gas permeable diffusers can be employed that are wettable by molten metal. When used as gas injectors, either in combination with ultrasonic oscillation or without, the gas permeable wettable diffusers can provide a high density of ultrafine inert gas bubbles that can be used to rapidly and efficiently reduce the level of dissolved hydrogen within the molten metal.

Abstract: An aluminum foam product that exhibits superior resistance to corrosion and oxidation in aqueous environments. The invention comprises the incorporation of chemical buffering agents, such as anhydrous borax (Na2B4O7), into the formulation of aluminum foam in amounts that effectively reduce the corrosion and oxidation in aqueous environments.

Abstract: A method for producing an aluminum foam product wherein reactive gas producing particles are introduced into an aluminum alloy melt under controlled conditions and subjected to agitation to induce the production of foam-stabilizing by-products, and, under certain conditions, the production of gases used to produce the molten metal foam itself. Foam products produced through this method have intrinsically formed metal oxides and other solid particles dispersed therein and are devoid of the large extrinsically added stabilizing ceramic additions traditionally used in the production of aluminum foams. The invention claims a rapid, single step method for producing an inoculated, foamable melt using low cost precursor materials.

Abstract: A method for producing an aluminum foam product wherein reactive gas producing particles are introduced into an aluminum alloy melt under controlled conditions and subjected to agitation to induce the production of foam-stabilizing by-products, and, under certain conditions, the production of gases used to produce the molten metal foam itself. Foam products produced through this method have intrinsically formed metal oxides and other solid particles dispersed therein and are devoid of the large extrinsically added stabilizing ceramic additions traditionally used in the production of aluminum foams. The invention claims a rapid, single step method for producing an inoculated, foamable melt using low cost precursor materials.

Abstract: A method of operating a twin wheel conform metal extrusion device or a cladding extrusion device for producing a composite of an extruded metal shell bonded to a metal foam core. A metal feedstock is extruded through an extrusion die defining a cavity housing a hollow extrusion mandrel to produce a metal shell. Liquid foam of a second metal is simultaneously delivered through the hollow mandrel bore such that the foam exiting the axial bore is metallurgically bonded to the metal extruded through the cavity.

Abstract: The present invention is directed to porous metal products including ceramic particles, where the initial surface layer (12) of the particles (10) is modified with agents that interact with surface oxygen, oxides and/or hydroxides to improve the wettability of particles within a molten metal alloy, and where the ceramic particles (10) are modified (14) by contacting the particles with a surface-modifying agent and heating the ceramic particles and surface-modifying agent to an elevated temperature at which the ceramic particle remains substantially stable and the surface-modifying agent becomes at least partially thermally unstable, to cause a reacted layer (16).

Abstract: This invention provides a method and apparatus for casting, hot rolling and annealing of non-heat treatable aluminum alloys which comprises continuously casting, hot rolling and, in-line with the hot rolling line, heating the aluminum sheet using infrared heat. The infrared heating system uses a control to assure that the aluminum alloy is heated to the proper temperature based on one or a number of process variables, such as hot rolling exit temperature, hot rolled product exit rate in terms of speed and product dimensions, and sheet temperature at the exit of the infrared heater. Variations in the infrared heating temperature can be tolerated in the product without deviating from target mechanical properties.

Abstract: The present invention is directed to a method for making porous aluminum product and products therefrom and, in particular, a method of rapidly solidifying a liquid metal foam produced by the incorporation of gas forming agents into an aluminum melt. The aluminum melt may be stabilized to support the creation of liquid metal foam by the addition of metal and/or ceramic additives. The decomposition of the gas forming agents and subsequent expansion of the gaseous products is controlled through the use of a reactor, wherein temperature, pressure and transit time can be adjusted to match the decomposition kinetics of the gas forming agent. The invention allows for the economical production of liquid metal foam of uniform cell size that can be continuously cast into sheet, plate and profile sections. Such metal foam products may be used in structural, thermal and acoustic applications.

Abstract: This invention provides a method and apparatus for casting, hot rolling and annealing of non-heat treatable aluminum alloys which comprises continuously casting, hot rolling and, in-line with the hot rolling line, heating the aluminum sheet using infrared heat. The infrared heating system uses a control to assure that the aluminum alloy is heated to the proper temperature based on one or a number of process variables, such as hot rolling exit temperature, hot rolled product exit rate in terms of speed and product dimensions, and sheet temperature at the exit of the infrared heater. Variations in the infrared heating temperature can be tolerated in the product without deviating from target mechanical properties.

Abstract: A method of operating a twin wheel conform metal extrusion device or a cladding extrusion device for producing a composite of an extruded metal shell bonded to a metal foam core. A metal feedstock is extruded through an extrusion die defining a cavity housing a hollow extrusion mandrel to produce a metal shell. Liquid foam of a second metal is simultaneously delivered through the hollow mandrel bore such that the foam exiting the axial bore is metallurgically bonded to the metal extruded through the cavity.

Abstract: A method of producing aluminum alloy sheet product includes casting a slab or ingot, homogenizing the cast slab, and hot rolling the homogenized slab to provide an intermediate gauge product. The temperature and other operating parameters of the hot rolling process are controlled so that the temperature of the ingot at the beginning of hot rolling is maintained at a temperature between 925° F. (496° C.) and 1025° F. (552° C.), and the temperature of the intermediate gauge product exiting the hot rolling step is between about 500° F. (260° C.) and 600° F. (316° C.). The intermediate gauge product is then subjected to a cold reduction of 45% to 70%, annealed, and cold rolled to final gauge.

Abstract: This invention provides a method and apparatus for casting, hot rolling and annealing of non-heat treatable aluminum alloys which comprises continuously casting, hot rolling, and, in-line with the hot rolling line, inductively heating the aluminum sheet. The induction heating system uses a feedback control to assure that the aluminum alloy is heated to the proper temperature based on one or a number of process variables, such as hot rolling exit temperature, hot rolled product exit rate in terms of speed and product dimensions, and sheet temperature at the exit of the induction heater. Variations in the induction heating temperature can be tolerated in the product without deviating from target mechanical properties.

Abstract: This invention provides a method and apparatus for casting, hot rolling and annealing of non-heat treatable aluminum alloys which comprises continuously casting, hot rolling, and, in-line with the hot rolling line, inductively heating the aluminum sheet. The induction heating system uses a feedback control to assure that the aluminum alloy is heated to the proper temperature based on one or a number of process variables, such as hot rolling exit temperature, hot rolled product exit rate in terms of speed and product dimensions, and sheet temperature at the exit of the induction heater. Variations in the induction heating temperature can be tolerated in the product without deviating from target mechanical properties.

Abstract: A method and apparatus for making aluminum alloy sheet product with improved paintbake response during automotive paintbake cycles, resistance to natural aging and better formability includes rapidly heating the aluminum alloy sheet product between a solution heat treating/quenching operation and a sheet coiling operation. Performing the rapid heating at this stage in the sheet manufacture minimizes the adverse effect of early natural aging (dwell time) on the paintbake response of these types of aluminum sheet alloy products. According to the invention, this dwell time is minimized by the application of a rapid heating step immediately following quenching from the solution heat treatment. After the aluminum sheet product has been rapidly heated, it is immediately coiled and cools under ambient conditions in coil form, this ambient cooling providing a pre-aging treatment which contributes to the improved performance of the sheet product in paintbake response, improved formability and natural aging resistance.

Abstract: A method of producing aluminum alloy sheet product includes casting a slab, homogenizing the cast slab, and hot rolling the homogenized slab to provide an intermediate gauge product. The temperature and other operating parameters of the hot rolling process are controlled so that the temperature of the intermediate gauge product exiting the hot rolling step is between about 500.degree. F. and 650.degree. F. Preferably, the temperature does not exceed 575.degree. F. The intermediate gauge product is then subjected to a cold reduction of 45% to 70%, annealed, and cold rolled to final gauge. The combination of controlling the hot rolling to provide a desired exit temperature of the intermediate gauge product and annealing prior to cold rolling to final gauge minimizes or eliminates the appearance of ridging or roping line defects in the aluminum sheet product when subjected to further straining in a forming or stamping operation.