Shaped metal body and method for producing a shaped metal body

Abstract

Method for manufacturing a multi-layered shaped metal body includes introducing gas into a molten metal in order to form a flowable metal foam, introducing the flowable metal foam into a mold containing therein at least one insert element comprising a freely shearing chain mail of loosely interlinked rings, and cooling the flowable metal foam in the mold to form a shaped metal body.

What is claimed: 
     
         1 . A method for manufacturing a multi-layered shaped metal body, said method comprising:
 introducing gas into a molten metal in order to form a flowable metal foam;   introducing the flowable metal foam into a mold containing therein at least one insert element comprising a freely shearing chain mail of loosely interlinked rings; and   cooling the flowable metal foam in the mold to form a shaped metal body.   
     
     
         2 . The method of  claim 1 , wherein the introducing comprises forcing into the mold the flowable metal foam. 
     
     
         3 . The method of  claim 1 , wherein the introducing comprises filling the mold with the flowable metal foam. 
     
     
         4 . The method of  claim 1 , further comprising:
 arranging the mold with a filling opening above the molten metal; and   connecting a cavity of the mold to a filler piece in a way to provide a liquid metal seal, with the filler piece protruding into the molten metal,   wherein the introducing comprises directing the flowable metal foam into the cavity of the mold through the filler piece.   
     
     
         5 . The method of  claim 1 , further comprising:
 pre-tensioning said at least one insert element before introducing the flowable metal foam.   
     
     
         6 . The method of  claim 1 , further comprising:
 controlling the introducing gas in such a way that pores of the flowable metal foam have a size increasing gradually or decreasing gradually.   
     
     
         7 . The method of  claim 1 , further comprising:
 applying a further layer of a homogeneous and/or isotropic material to one side face of the shaped metal body.   
     
     
         8 . The method of  claim 1 , wherein the freely shearing chain mail of loosely interconnected rings are structured and arranged to at least one of:
 shear completely freely in all directions; and   slide on one another in the metal foam matrix upon loading.   
     
     
         9 . A method for manufacturing a multi-layered shaped metal body comprising a metal foam matrix, at least one insert element embedded within the metal foam matrix, the metal foam matrix and the insert element being positively connected to each other, and the insert element comprises a freely shearing chain mail of loosely interconnected rings, said method comprising:
 placing the at least one insert element in a mold, said mold having a filling opening above a liquid metal melt;   connecting a cavity of the mold to a filler piece;   causing the flowable metal foam to rise up through the filler piece and the filling opening into the cavity of the mold.   
     
     
         10 . The method of  claim 9 , wherein the freely shearing chain mail of loosely interconnected rings are positively connected to form an interlinked part. 
     
     
         11 . The method of  claim 9 , wherein the at least one insert element comprises plural insert elements arranged next to one another or one behind another within the metal foam matrix. 
     
     
         12 . The method of  claim 9 , wherein the metal foam matrix has an essentially monomodal pore size distribution. 
     
     
         13 . The method of  claim 9 , wherein the metal foam matrix has pores, said pores having sizes increasing gradually from one side face of the shaped metal body to an opposite side face. 
     
     
         14 . The method of  claim 9 , further comprising:
 arranging a material layer on one side face of the shaped metal body, said material layer comprising a homogeneous and/or isotropic material.   
     
     
         15 . The method of  claim 9 , further comprising:
 arranging a material layer on one side face of the shaped metal body, said material layer comprising a sheet of mineral material.   
     
     
         16 . The method of  claim 9 , further comprising:
 forming, with the multi-layer shaped metal body, a ballistic-resistant rigid shaped part.   
     
     
         17 . The method of  claim 9 , wherein the method utilizes material bonding by adhesion between the at least one insert element and the metal foam matrix and said material bonding occurs only up to a maximum of about 30% relative to a rupturing resistance and pulling apart strength. 
     
     
         18 . The method of  claim 9 , wherein the freely shearing chain mail of loosely interconnected rings are structured and arranged to at least one of:
 shear completely freely in all directions; and   slide on one another in the metal foam matrix upon loading.   
     
     
         19 . A method for manufacturing a multi-layered shaped metal body, said method comprising:
 introducing a flowable metal foam into a mold containing at least one insert element comprising a freely shearing chain mail of loosely interlinked rings; and   cooling the flowable metal foam in the mold to form a shaped metal body,   wherein, after the cooling, the at least one insert element is materially bonded by adhesion to a metal foam matrix only up to a maximum of about 30% relative to a rupturing resistance and pulling apart strength.   
     
     
         20 . The method of  claim 19 , wherein the introducing comprises:
 connecting a cavity of the mold to a filler piece in a way that provides a liquid metal seal, with the filler piece protruding into a liquid metal melt; and   causing the liquid metal melt to rise up through the filler piece and the filling opening into the cavity of the mold with the flowable metal foam.   
     
     
         21 . The method of  claim 19 , wherein the freely shearing chain mail of loosely interconnected rings are structured and arranged to at least one of:
 shear completely freely in all directions; and   slide on one another in the metal foam matrix upon loading.