Metal founding – Process – Shaping liquid metal against a forming surface
Patent
1995-10-04
1997-05-27
Lin, Kuang Y.
Metal founding
Process
Shaping liquid metal against a forming surface
75415, B22D 2700
Patent
active
056323190
ABSTRACT:
A process for making high-quality foamed aluminum articles is disclosed. This process comprises the step of: (a) placing a raw aluminum feedstock into a mold, the raw aluminum feed stock contains at least 50 wt % spent (i.e., recycled) aluminum and does not contain any extraneous viscosity enhancing agent such as metallic calcuim or magnesium; (b) heating the mold so as to melt the raw aluminum feedstock to form a liquid aluminum mass; (c) stirring the liquid aluminum mass in open air to increase its viscosity by a factor of at least about 1.3 to 1.8; (d) adding a foaming agent into the liquid aluminum mass; (e) continuing stirring the liquid aluminum mass containing the foaming agent so as to generate and uniformly distribute gas bubbles inside said liquid aluminum mass; and (f) cooling and solidifying the liquid aluminum mass to room temperature so as to form the foamed aluminum article. In a preferred embodiment, recycled foamed aluminum materials are used as the raw aluminum feedstock. The foamed aluminum article has a porosity of at least 80%, a specificity density of no greater than 0.45, and an average pore size between 3 and 6 min. Because the process is self-thickening, and no extraneous thickeners such as calcium metal are needed, great economic benefits can be obtained without adversely affecting the quality of the final product.
REFERENCES:
patent: 3671221 (1972-06-01), Berry
patent: 3725037 (1973-04-01), Berry et al.
patent: 4713277 (1987-12-01), Akiyama et al.
Chiou Ting-Huey
Chueh Shan-Chang
Su Kou-Chang
Yang Chin-Chen
Industrial Technology Research Institute
Liauh W. Wayne
Lin Kuang Y.
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