CA2713560C - Process and method for producing foamable metals - Google Patents

Process and method for producing foamable metals Download PDF

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Publication number
CA2713560C
CA2713560C CA2713560A CA2713560A CA2713560C CA 2713560 C CA2713560 C CA 2713560C CA 2713560 A CA2713560 A CA 2713560A CA 2713560 A CA2713560 A CA 2713560A CA 2713560 C CA2713560 C CA 2713560C
Authority
CA
Canada
Prior art keywords
metal
foamable
metal article
mixture
producing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA2713560A
Other languages
French (fr)
Other versions
CA2713560A1 (en
Inventor
Philip Mavrinac
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
PENNA METALS INTERNATIONAL Inc
Original Assignee
PENNA METALS INTERNATIONAL Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by PENNA METALS INTERNATIONAL Inc filed Critical PENNA METALS INTERNATIONAL Inc
Priority to CA2713560A priority Critical patent/CA2713560C/en
Priority to BR112013005739A priority patent/BR112013005739A2/en
Priority to PCT/CA2011/000931 priority patent/WO2012024770A1/en
Priority to US13/817,993 priority patent/US20130294958A1/en
Publication of CA2713560A1 publication Critical patent/CA2713560A1/en
Application granted granted Critical
Publication of CA2713560C publication Critical patent/CA2713560C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K47/00Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/02Inorganic compounds
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M15/00Inhalators
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/11Making porous workpieces or articles
    • B22F3/1121Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1125Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium

Abstract

A process for producing foamable metal articles and foamed metal articles and materials.
A mixture of foamable material is produced by blending at least one metal powder and gas-producing blowing agents then compacting the mixture into a solid form of various cross-sections and configurations. The gas-producing agent comprises some combination of silicon powder and talc powder (Si, [H2Mg3(SiO3)4] or [Mg3Si4O10(OH)2]).

Description

PROCESS AND METHOD FOR PRODUCING FOAMABLE METALS
TECHNICAL FIELD
The present invention relates to a process for producing foamable materials and foamed metal articles. More particularly, the present invention relates to mixtures of foamable metal materials produced from at least one metal powder and gas-producing blowing agents.
BACKGROUND OF THE INVENTION
The production of foamed metal articles is known in the art. There are a variety of patents and publications concerning the production of foamed metal articles, devices and processes for producing said articles, and the metal/foaming agent mixtures used therein. The number of applications for foamed metals is high, including, but not limited to, stiffening of hollow structures, sound and vibration dampening, inhibition of energy flows, and creation of decorative elements.
Current methods of closed-cell foamed metal article production, however, typically result in cells that are irregular and coarse, often with the "windows" of the gas bubbles appearing to be fissured. In addition, prior art methods usually result in a substantial amount of unfoamed metal material at the base of the foamed metal article.
Accordingly, there is a need in the art for an improved metal/foaming agent mixture and process for the production of foamed metal articles, that results in more thorough and consistent cell formation in the foamed metal article.
1 of 8 SUMMARY OF THE INVENTION
This invention is directed to an improved process for producing foamable and foamed metal articles, and an improvement of the industrial properties of the foamable products and of the closed-cell foamed metal articles by comparison with the prior art.
In one exemplary embodiment, the present invention comprises a process for producing foamable metal articles, the process comprising producing a mixture of at least one metal powder and gas-producing blowing agents, and compacting the mixture to a semi-finished foamable product or article or precursor, wherein the gas-producing blowing agent mixture contains some combination of silicon powder and talc powder (Si, [H2Mg3(SiO3)4] or [Mg3Si4010(OH)2]).
In another exemplary embodiment, the present invention comprises a process of producing a foamed metal article, the process comprising subjecting the aforesaid compacted mixture and/or fomable product to conditions (e.g., elevated temperature, and/or elevated or reduced pressure) effective to foam said mixture.
In yet another exemplary embodiment, the present invention comprises the foamed metal articles produced by said processes.
Still other advantages of various embodiments will become apparent to those skilled in this art from the following description wherein there are shown and described exemplary embodiments of this invention simply for the purposes of illustration. As will be realized, the invention is capable of other different aspects and embodiments without departing from the scope of the invention. Accordingly, the advantages, drawings, and descriptions are illustrative in nature and not restrictive in nature.
2 of 8 BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic illustration of a process for producing foamable metal articles and foamed metal articles in accordance with an exemplary embodiment of the present invention.
Figures 2 and 3 show a cross-section of a foamed metal article produced in accordance with one embodiment of the present invention.
Figure 4 shows a cross-section of a foamed metal article produced in accordance with prior art techniques.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Figure 1 shows an exemplary embodiment of a process for producing foamable metal articles and foamed metal articles in accordance with the present invention. At least one metal powder 10 is mixed with a gas-producing blowing agent 12 containing some combination of silicon powder and talc powder (Si, [H2Mg3(SiO3)4] or [Mg3Si4010(OH)2]). While other gas-producing blowing agents (e.g., titanium hydride, carbonates, and hydrates) have been used for producing foamable metal articles, the use of the combination of silicon powder and talc powder is not known in the art.
The combination of the metal powder 10 and the gas-producing blowing agents 12 is blended 20 and compacted 30 to form compressed foamable metal articles 40 useful for producing foamed metal articles 70. The foamable metal articles then may be exposed to elevated temperature 50, and/or elevated or reduced pressure, effective to cause the foamable metal article to foam. The material is then cooled 60, if necessary.
3 of 8 In an alternative embodiment, the foamable metal article is placed in a mold and foamed therein.
The foamed metal articles produced with the aid of the gas-producing blowing agent 12 in accordance with the present invention, especially produced auto-catalytically, .. have a morphology differing from that of foams obtained using prior art foaming agents (for example, titanium hydride, magnesium hydride). The foamed metal articles produced by the foamable metal articles/precursors obtained by means of the processes described herein have a very homogenous pore density distribution extending into the surface regions of the shaped foamed metal article, as seen in Figures 2 and 3. Figures 2 and 3 show an aluminum foamed product produced according to the present invention using 10% Silicon powder and 1% Talc powder as the gas-producing blowing agents mixture, and aluminum metal powder (percentages are by weight of the blended mixture).
This represents a considerable advance over foamed metal articles formed using prior art methods and prior art gas-producing blowing agents. An example of an aluminum foamed metal article produced using prior art techniques, using 1%
titanium hydride as the gas-producing blowing agent, is shown in Figure 4. The compaction and foaming conditions were identical with the process used to produce the article shown in Figures 2 and 3.
Figures 2 through 4 show a cross-section of the respective foamed metal articles, cut transversely. The foamed metal article produced using titanium hydride in accordance with the prior art shows extensive compaction (i.e., a substantial layer of unfoamed material) of the base zone 30 along the bottom of the article (see Figure 4).
The cell distribution in the foamed structure is very irregular, and the cells themselves are
4 of 8 mainly coarse, and some have risen. This results in a somewhat fissured surface of the metal article, where large gas bubbles of this type have "blown off' on the surface.
In contrast, the foamed article produced in accordance with the present invention (shown in Figures 2 and 3) distinctly shows more uniform foaming. The compacted base zone 26 is only approximately 0.25 mm thick, a marked improvement over the up to 10 mm thick base zone 30 shown in the prior art material (Figure 4). In addition, the number of cells per unit volume in the foamed article produced in accordance with the present invention is distinctly greater, specifically with preference for the presence of small cells 28. Irregularity of cells is distinctly less pronounced than in the prior-art article, and the openings are finer and more uniform.
Examination of the structures of the cells in the foamed articles shown in Figures 2-4 reveals a peculiarity of the prior art metal foam (Figure 4). As seen in Figure 4, the openings in the "windows" of the gas bubbles frequently appear to be fissured 32, whereas virtually no such sites are evident in the foam of the present invention (Figures 2 and 3). This indicates that, at the time when the volume of the metal changed, the viscosity of the material foamed according to the prior art is less than that of the material foamed according to the invention. A possible reason for this is that titanium hydride increases the viscosity of the surrounding metal (in this case, aluminum), while the gas-producing blowing agent of the present invention has had a contrary effect.
It is possible to foam all fusible metals or metal alloys in accordance with the method described herein. In one exemplary embodiment, the metal powder particularly preferably employed for the purpose of the present invention is aluminum and its alloys.
In this embodiment, the metal powder comprises essentially aluminum, and where
5 of 8 appropriate, conventional alloying constituents including, but not limited to, magnesium, copper, and/or silicon.
Thus, it should be understood that the embodiments and examples have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art. Accordingly, it is intended that the scope of .. the invention be defined by the claims appended hereto.
6 of 8

Claims (9)

We claim:
1. A process for producing a foamable metal article comprising the steps of:
blending a mixture of at least one metal powder and gas-producing blowing agents; and heat compacting the mixture at a temperature below the decomposition temperature of the mixture to form a foamable metal article;
wherein the gas-producing blowing agents comprises silicon powder and talc-powder present a concentration ranging from about 0.1% to about 12% by weight of the mixture.
2. The process according to claim 1, wherein the metal powder comprises aluminum or aluminum alloyed with one or more alloying constituents.
3. The process according to claim 1 or 2, wherein the compacting is carried out by rolling, extrusion or a combination of both.
4. The process according to any one of claims 1 to 3, wherein the mixture is compacted to a density of at least 90% of the theoretical density of the metal in the metal powder.
5. The process according to any one of claims 1 to 3, wherein the mixture is compacted to a density of at least 95% of the theoretical density of the metal in the metal powder.
6. The process according to any one of claims 1 to 5, further comprising the step of:
exposing the foamable metal article to elevated temperature, and/or elevated or reduced pressure, effective to cause the foamable metal article to foam.
7. A process for preparing a foamed metal article, wherein a foamable metal article is prepared according to the process of any one of claims 1 to 5, further comprising the steps of:
placing said foamable metal article in a mold; and exposing the foamable metal article to elevated temperature, and/or elevated or reduced pressure, effective to cause the foamable metal article to foam into a foamed metal article.
8. A foamable metal article produced by the process according to any one of claims 1 to 6.
9. A foamed metal article produced by the process according to claim 7.
CA2713560A 2010-08-23 2010-08-23 Process and method for producing foamable metals Expired - Fee Related CA2713560C (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
CA2713560A CA2713560C (en) 2010-08-23 2010-08-23 Process and method for producing foamable metals
BR112013005739A BR112013005739A2 (en) 2010-08-23 2011-08-19 process and method for producing foamable metals.
PCT/CA2011/000931 WO2012024770A1 (en) 2010-08-23 2011-08-19 Process and method for producing foamable metals
US13/817,993 US20130294958A1 (en) 2010-08-23 2011-08-19 Process and Method For Producing Foamable Metals

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA2713560A CA2713560C (en) 2010-08-23 2010-08-23 Process and method for producing foamable metals

Publications (2)

Publication Number Publication Date
CA2713560A1 CA2713560A1 (en) 2012-02-23
CA2713560C true CA2713560C (en) 2019-10-29

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2713560A Expired - Fee Related CA2713560C (en) 2010-08-23 2010-08-23 Process and method for producing foamable metals

Country Status (4)

Country Link
US (1) US20130294958A1 (en)
BR (1) BR112013005739A2 (en)
CA (1) CA2713560C (en)
WO (1) WO2012024770A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016067252A1 (en) 2014-10-31 2016-05-06 Glaxosmithkline Intellectual Property Development Limited Powder formulation

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3087807A (en) * 1959-12-04 1963-04-30 United Aircraft Corp Method of making foamed metal
DE4124591C1 (en) * 1991-01-21 1993-02-11 Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung Ev, 8000 Muenchen, De Foamable metal body prodn. with reduced density differences - by charging hollow section with mixt. of powder contg. expanding agent and metal powder, and precompacting
DE4206303C1 (en) * 1992-02-28 1993-06-17 Mepura Metallpulver Ges.M.B.H., Ranshofen, At
ES2193439T3 (en) * 1997-06-10 2003-11-01 Goldschmidt Ag Th FOAM METAL BODY.
JP4189401B2 (en) * 2005-10-05 2008-12-03 本田技研工業株式会社 Method for producing foamed aluminum
US20110111251A1 (en) * 2009-11-10 2011-05-12 Ken Evans Process for producing a foamed metal article and process for producing a foamable metal precursor

Also Published As

Publication number Publication date
WO2012024770A1 (en) 2012-03-01
US20130294958A1 (en) 2013-11-07
BR112013005739A2 (en) 2016-05-03
CA2713560A1 (en) 2012-02-23

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