Abstract: A premix composition for producing an inorganic solid foamed mass by mixing component (A) an aqueous acidic phosphate solution of mainly polyvalent cations and phosphoric acid wherein between 0.8 and 1.75 protons of the phosphoric acid molecule of said phosphate are neutralized by the cations, which also contains one or more fillers dispersed therein, with (B) an oxide, hydroxide or polyvalent salt of a weak acid as hardener and a carbonate foaming agent. A process of producing an inorganic foamed mass using the premix composition and a solid foamed mass produced by the process are also disclosed. The process produces a relatively elastic cross-linked structure due to mainly the secondary phosphates being neutralized versus the tertiary phosphate groups.

Abstract: A method for consolidating powdered material to near net shape and full density is provided. The method includes the steps of: mixing a particulate material with an organic or inorganic binder to form a mold material; shaping the mold material into a mold having a shape and including an external surface and an interior cavity and being of sufficient solidity to maintain its shape yet being compressible under pressure; filling the interior cavity with a powdered material to be consolidated; heating the mold with the powdered material therein to form a heated filled mold; applying pressure to the external surface of the mold sufficient to compress the mold material and transfer a pressurizing force to the powdered material within the mold cavity so as to consolidate the powder and form an article; and removing the article from the mold. In an alternative method, the mold material is made of a particulate material which is held in the shape of the mold by a vacuum.

Abstract: Lightweight aggregate for use in the building industry is produced by pelletizing or granulating pulverized fuel ash or other siliceous material with a binder comprising lime in an amount less than 5% by weight based on the weight of the mixture of lime and siliceous material and curing the pellets or granules at a temperature within the range of from 35.degree. C. to 100.degree. C. in an atmosphere saturated with water vapor. The amount of lime added as binder is preferably within the range of from 1 to 4.5% by weight and curing temperature is preferably within the range of from 50.degree. to 85.degree. C. Preferably the pelletizing process is also carried out at an elevated temperature within the range of from 35.degree. C. to 100.degree. C.