Abstract: The invention relates to a process for producing a particle-stabilized metal foam from a composite capable of acting as a precursor composite for the metal foam. The precursor composite is formed by heating a matrix metal, e.g. aluminum or an aluminum alloy, above its liquidus temperature to form a liquid matrix metal, adding to the liquid matrix metal stabilizer particles capable of remaining dispersed within the matrix metal, e.g. MgO particles preferably in the form of agglomerates of particles and some fine particles, and mixing the liquid matrix metal and stabilizer particles under a covering gas, e.g. air, in such a way that bubbles of the gas, as well as the stabilizing particles, are dispersed throughout the matrix metal. The precursor composite can then be foamed by the introduction of a gas by a known technique to form a particle-stabilized metal foam.

Abstract: A method is disclosed for forming a foamed aluminum article. A foaming vessel is used including a peripheral wall and a plurality of vertical rod members to form mounting holes at given positions in the vicinity of the inside surface of the peripheral wall. The melt of aluminum or its alloy is stirred with a viscosity increaser and a foaming material. The solidified aluminum block is then sliced to a given thickness to obtain a product of foamed aluminum having mounting holes in given positions in the vicinity of the outer edge thereof. A hard portion around the holes is used as the surface site for mounting the product. The products are used for sound and heat insulation.

Abstract: A process for the production of foamable elements, in which a metal powder is mixed with a foaming agent powder, the powder mixture is brought to an elevated temperature in a receiver and is extruded through a die, so that the extruded part can be subsequently foamed by decomposition of the foaming agent powder by heating of the extruded part and then cooled to yield a finished foam element. The powder mixture is continuously introduced into a channel, leading to the die, which has a moving wall component by which the powder mixture is transported in the channel by friction with precompacting and is extruded through the die. The speed of the wall component is selected so that the heating necessary for the precompacting comes from heat generated in the transport operation.

Abstract: A process and apparatus are described for manufacturing particle stabilized foamed metal slabs. A foam is first formed in a foaming chamber by heating a composite of a metal matrix and finely divided solid stabilizer particles above the solidus temperature of the metal matrix and discharging gas bubbles into the molten metal composite below the surface thereof to thereby form a stabilized liquid foam on the surface of the molten metal composite. The stabilized liquid foam is continuously drawn off the surface of the molten metal composite and is solidified into a shaped foam product while being continuously drawn off.

Abstract: Shaped articles are produced from foam metal by a procedure wherein the foam is formed by heating a composite of a metal matrix and finely divided solid stabilizer particles above the solidus temperature of the metal matrix and discharging gas bubbles into the molten metal composite below the surface thereof to thereby form a stabilized liquid foam on the surface of the molten metal composite. According to the novel feature the stabilized metal foam in liquid form is shape cast by being pressed into a mould and permitted to cool and solidify. The density of the cast part is essentially unchanged from that of the starting liquid foam.

Abstract: A novel lightweight gas metal composite is produced having isolated particle stabilized pores. A composite of a metal matrix, e.g. aluminum, and finely divided solid stabilizer particles, e.g. silicon carbide, is heated above the liquidus temperature of the metal matrix and this is mixed such that a vortex is formed. The molten composite is blanketed with a gas and during the vortex mixing. This gas is drawn into the melt to produce an expanded, viscous molten composite material containing pores which are very small, spherical-shaped and quite evenly distributed. The viscous molten composite material can be directly formed into a solid shaped product and is also capable of being remelted and formed by forming processes without destroying the integrity of the pores. The result is a lightweight expanded metal product capable of being formed into shapes to close dimensional tolerances.

Abstract: A method for forming a porous body of a metal from the group consisting of molybdenum, molybdenum alloy, tungsten, tungsten alloy, or mixtures thereof comprises foaming a mixture of a sinterable powder of the metal and a foaming agent in a volume ratio of about 0.6 to 3.5:1 respectively, to form a foam having the metal powder dispersed therein. The foam is heated in a reducing atmosphere that promotes interparticle diffusion and bonding, to decompose the foam and sinter the metal powder to form the porous body.

Abstract: A method is described for producing foamed metal in which gaseous bubbles are retained within a mass of molten metal during foaming. The method comprises heating a composite of a metal matrix and finely divided solid stabilizer particles above the liquidus temperature of the metal matrix, discharging gas bubbles into the molten metal composite below the surface thereof to thereby form a foamed melt on the surface of the molten metal composite and cooling the foamed melt thus formed below the solidus temperature of the melt to form a solid foamed metal having a plurality of closed cells. A novel foamed metal product is also described.

Abstract: Normally reject sponge metal fines, especially those produced by the crushing and screening of a regulus of zirconium and/or hafnium metal sponge, are added to the initial reduction charge of the metal tetrachloride and magnesium metal, and the so-modified charge is then passed through the conventional reduction and vacuum distillation steps to produce a regulus of the metal that has the reject fines incorporated therein by sintering.

Abstract: A method is described for producing foamed metal in which gaseous bubbles are retained within a mass of molten metal during foaming. The method comprises heating a composite of a metal matrix and finely divided solid stabilizer particles above the liquidus temperature of the metal matrix, discharging gas bubbles into the molten metal composite below the surface thereof to thereby form a foamed melt on the surface of the molten metal composite and cooling the foamed melt thus formed below the solidus temperature of the melt to form a solid foamed metal having a plurality of closed cells.

Abstract: The invention provides a nickel foam and a method of forming a nickel foam for a nickel containing battery. An open-cell foam structure is placed in a nickel carbonyl gas containing structure. The foam structure is heated to a temperature at which nickel carbonyl decomposes. Nickel from the nickel carbonyl gas decomposes on the foam structure to form a nickel plated foam structure. The nickel plated foam structure is then sintered leaving an open-cell nickel network to form the nickel foam. The open-cells of the nickel foam comprise substantially hollow wires having a substantially uniform transverse cross-section. The nickel foam is further characterized by the conductivity through the nickel foam multiplied by a factor of 3.4 being equal to or greater than the theoretical conductivity of nickel.