Method for making ultra-lightweigh structual metals

a technology of structual metals and metals, applied in the field of porous metallic objects, can solve the problems of poor rigidity of materials, high cost, and difficult to achieve complex three-dimensional shapes, and achieve the effect of better than expected physical properties
US20080223539A1Inactive Publication Date: 2008-09-18COOPER DR KHERSHED P +3
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Patent Information

Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
COOPER DR KHERSHED P
Publication Date
2008-09-18
Estimated Expiration
Not applicable · inactive patent

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Abstract

This invention pertains to a product and a method for making the product. The product is a lightweight solid porous metallic product containing small solid spheres having a coating of a primary alpha phase thereon disposed in a solid metal alloy eutectic matrix. The method includes the steps of mixing the hollow rigid spheres and a metal alloy, which metal alloy can be preheated to render it molten, in order to form a dispersion of the spheres distributed in the molten alloy; initially cooling the dispersion to render it semi-solid whereby the spheres are coated by a solid and the coated spheres are disposed in the semi-solid mixture of the solid and liquid; and finally cooling the sphere-containing semi-solid mixture to a temperature at which the sphere-containing semi-solid mixture becomes solid and the product is formed.
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Description

FIELD OF THE INVENTION

[0001] This invention pertains to the field of porous metallic objects and preparation thereof that is characterized by the use of small hollow spheres in a semi-solid mixture in a metal alloy.DESCRIPTION OF THE RELATED ART

[0002] Lightweight or porous metallic materials and structures are made in honeycomb and foam core forms. Other examples are linear cellular metals and metal wire trusses. Most of these materials are made in simple shapes such as two-dimensional panels and one-dimensional bars and rods. Making these into complex three-dimensional shapes is very difficult and cost intensive. This is because of the nature of the processing routes for these materials. These materials are expensive to fabricate because they require several processing steps. Honeycomb structures are made by epoxy joining or brazing together a honeycomb arrangement made by folding thin metal ribbons. This forms the honeycomb core to which are joined face panels to make a sandwich str...

Claims

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