Abstract: New aluminum alloys having magnesium and zinc are disclosed. The new magnesium-zinc aluminum alloys may include from 2.5 to 4.0 wt. % Mg, from 2.25 to 4.0 wt. % Zn, wherein (wt. % Mg/wt. % Zn)?1.0, and wherein (wt. % Mg/wt. % Zn)?1.6, from 0.20 to 0.9 wt. % Mn, from 0.10 to 0.40 wt. % Cu, up to 1.0 wt. % Li, up to 0.50 wt. % Fe, up to 0.50 wt. % Si, and optional secondary element(s), the balance being aluminum, optional incidental elements and impurities.

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: 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: 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: 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: A method and apparatus for reducing crop losses during slab and ingot rolling concerns the formation of a slab ingot having a specially configured or shaped butt end and optionally a head end as well. A special shape is formed by machining, forging or preferably by casting. The special shape at the butt end is imparted during casting by a specially shaped bottom block or starter block. The special shape of the bottom block is imparted to the cast ingot butt end. The specially shaped butt end of a slab shaped ingot is generally rectangular in shape and has longitudinally outwardly extending, enlarged portions, which slope downwardly toward a depressed central valley region. The lateral sides of the enlarged end portions and the depressed valley region carry transversely extending, tapered or curved edges. A similar shape may be imparted to the head end of the ingot at the conclusion of a casting run through the use of a specially shaped hot top mold or by way of machining or forging the cast head end.