Process and Method For Producing Foamable Metals

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 one gas-producing blowing agent, then compacting the mixture into a solid form of various cross-sections and configurations. The gas-producing blowing agent comprises silicon powder and talc powder.

1 . A process for producing a foamed metal article, comprising the steps of:
 blending a mixture of at least one metal powder and one gas-producing blowing agent;   and compacting the mixture to form a foamable metal article,   wherein the gas-producing blowing agent comprises one or more reactive powder materials.   
     
     
         2 . The process of  claim 1 , wherein the gas-producing blowing agent comprises silicon powder or talc powder or a combination thereof. 
     
     
         3 . The process of  claim 1 , wherein the metal powder comprises essentially aluminum, or aluminum alloyed with one or more conventional alloying constituents. 
     
     
         4 . The process of claim wherein the compacting is carried out by rolling, extrusion, or a combination of both. 
     
     
         5 . The process of  claim 1 , wherein the compacting is carried out below the decomposition temperature of the gas-producing blowing agent mixture. 
     
     
         6 . The process of  claim 1 , wherein the compacting is carried out at room temperature. 
     
     
         7 . The process of  claim 1 , wherein the mixture is compacted to a density of at least 90% of the theoretical density of the metal in the metal powder. 
     
     
         8 . The process of  claim 1 , wherein the mixture is compacted to a density of at least 95% of the theoretical density of the metal in the metal powder. 
     
     
         9 . The process of  claim 1 , wherein the gas-producing blowing agent is from 0.1% to 12% by weight of the mixture. 
     
     
         10 . The process of  claim 1 , 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.   
     
     
         11 . The process of  claims 1 , 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.   
     
     
         12 . A foamable metal article produced by the process of  claim 1 . 
     
     
         13 . A foamed metal article produced by the process of  claim 10 .