The present invention provides a casting having increased crashworthiness including an an aluminum alloy of about 6.0 wt % to about 8.0 wt % Si; about 0.12 wt % to about 0.25 wt % Mg; less than or equal to about 0.35 wt % Cu; less than or equal to about 4.0 wt % Zn; less than or equal to about 0.6 wt % Mn; and less than or equal to about 0.15 wt % Fe, wherein the cast body is treated to a T5 or T6 temper and has a tensile strength ranging from 100 MPa to 180 MPa and has a critical fracture strain greater than 10%. The present invention further provides a method of forming a casting having increased crashworthiness.

A HIGH CRASHWORTHINESS AL-SI-Mg ALLOY AND METHODS FOR PRODUCING AUTOMOTIVE CASTING

A method for producing an aluminum foam product wherein reactive gas producing particles are introduced into an aluminum alloy melt under controlled conditions and subjected to agitation to induce the production of foam-stabilizing by-products, and, under certain conditions, the production of gases used to produce the molten metal foam itself. Foam products produced through this method have intrinsically formed metal oxides and other solid particles dispersed therein and are devoid of the large extrinsically added stabilizing ceramic additions traditionally used in the production of aluminum foams. The invention claims a rapid, single step method for producing an inoculated, foamable melt using low cost precursor materials.

Method for producing foamed aluminum products by use of selected carbonate decomposition products

An aluminum casting alloy, comprises, in weight percent, about 4-9% Zn; about 1-4% Mg; about 1-2.5% Cu; less than about 0.1% Si; less than about 0.12% Fe; less than about 0.5% Mn; about 0.01-0.05% B; less than about 0.15% Ti; about 0.05-0.2% Zr; about 0.1-0.5% Sc; no more than about 0.05% each miscellaneous element or impurity; no more tha about 0.15% total miscellaneous elements or impurities.

AN Al-Zn-Mg-Cu-Sc HIGH STRENGTH ALLOY FOR AEROSPACE AND AUTOMOTIVE CASTINGS

A reactive material comprising a polymer and a metal foam is provided. The strength of the reactive material is increased by the inclusion of the metal foam. Also provided is a method of making a reactive material by including a metal foam therein and ordnance containing the reactive material. A preferred reactive material includes polytetrafluoroethylene (PTFE) and an aluminum foam.

Reinforced reactive material

A method for producing an aluminum foam product wherein reactive gas producing particles are introduced into an aluminum alloy melt under controlled conditions and subjected to agitation to induce the production of foam-stabilizing by-products (20), and, under certain conditions, the production of gases (15) used to produce the molten metal foam itself. Foam products produced through this method have intrinsically formed metal oxides (20) and other solid particles dispersed therein and are devoid of the large extrinsically added stabilizing ceramic additions traditionally used in the production of aluminum foams. The invention claims a rapid, single step method for producing an inoculated, foamable melt using low cost precursor materials.

Method for producing foamed aluminum using carbonates

The present invention is directed to a method for making porous aluminum product and products therefrom and, in particular, a method of rapidly solidifying a liquid metal foam produced by the incorporation of gas forming agents into an aluminum melt. The aluminum melt may be stabilized to support the creation of liquid metal foam by the addition of metal and/or ceramic additives. The decomposition of the gas forming agents and subsequent expansion of the gaseous products is controlled through the use of a reactor, wherein temperature, pressure and transit time can be adjusted to match the decomposition kinetics of the gas forming agent. The invention allows for the economical production of liquid metal foam of uniform cell size that can be continuously cast into sheet, plate and profile sections. Such metal foam products may be used in structural, thermal and acoustic applications.

David Leon

Papers

Method for producing foamed aluminum products