A foamed metal which has an apparent specific gravity of from 0.2 to 0.8 and comprises an aggregate of polygonal closed cells of from 2 to 10 mm in average diameter. The foamed metal is not only light in weight, free of directionality and structurally strong but also excellent in sound-absorbing and electromagnetic shielding properties, and is useful as constructional, structural or functional material. A method for producing the foamed material comprises adding calcium as a thickening agent to molten aluminum or alloy thereof in an amount of from 0.2 to 8% by weight, followed by agitating to adjust the viscosity of the melet, then adding from 1 to 3% by weight of powdered titanium hydride as a foaming agent to the melt, and agitating the melt to effect foaming.

Foamed metal and method of producing same

A system and method of manufacture providing reinforced structurally functional load-bearing members, including but not limited to using thermoplastic materials, such as High Density Polyethylene (HDPE), reinforced such as with an aluminum alloy or carbon fiber core element. Among its possible uses, the present invention has application for provision of structural support members, such as an illustrative I joist product having a vertical center member preferably comprising HDPE, and top and bottom flanges having structurally meaningful reinforcement. The center member and flanges prefera+y comprising HDPE provides a relatively hard, durable, substantially weather-resistant structure.

Engineered structural members and methods for constructing same

An improved damping or reinforcement structure (20) and method of making the same, comprising a wall (14) of a first material, a layer of adhesive (22) bonded to the first material, and a layer of a metal foam (12) bonded to the adhesive (22).

Composite metal foam damping/reinforcement structure

Perforated plate armor (10) for protecting an object (12) from damage includes outer and inner perforated steel plates (14) and (18) which have associated patterns of holes (16, 20). These perforated steel plates (14, 18) are heat treated to have hardened surfaces and a more ductile core and are spaced with respect to each other at outer and inner locations with respect to the object (12) to be protected. The patterns of holes (16, 20) of the perforated steel plates (14, 18) are offset with respect to each other to prevent straight line penetration of any particle through both plates. An inner backing plate (28) preferably made of aluminum is also provided to stop any particles that might penetrate both perforated steel plates (14, 18). Fillers (22, 24) and connectors (26) space the outer and inner perforated steel plates (14, 18) and the aluminum backing plate (28) with respect to each other.

Perforated plate armor

A light weight composite panel for use in vaults or strong rooms, having a foamed plastic core, metal mesh embedded in the major faces of the core, a layer of wood on each face of the plastic core, and a sheet metal skin covering the layers of wood. An inner one of the sheet metal skins is preferably a heat conductive metal, such as aluminum.

Light weight vault wall

A COMPOSITE SANDWICH PANEL TYPE CONSTRUCTION COMPRISING TWO INDEPENDENT OUTER LAYERS ATTACHED TO OPPOSITE SIDES OF FOAMED METAL CORE, SAID CORE HAVING Z-SHAPED REINFORCING ELEMENTS THEREIN. A PREFERRED PANEL CONSTRUCTION HAS ONE OUTER LAYER EXTENDING AROUND SAID FOAMED METAL CORE SO AS TO SUBSTATALLY ENCASE SAID CORE, METHODS OF FABRICATING SUCH A PANEL CONSTRUCTION (1) BY CASTING SAID FOAMED ALUMINUM AROUND SAID REINFORCING ELEMENTS AND SUBSEQUENTLY ATTACHING SAID OUTER LAYERS TO THIS INTERAL METAL FOAM/REINFORCING ELEMENT CORE STRUCTURE, AND (2) BY FIRST PREPARING SAID CORE FROM INDIVIDUAL METAL FOAM PIECES WHICH ARE THEN ATTACHED TO PERFORMED Z-SHAPED REINFORCING ELEMENTS, SAID ASSEMBLED CORE STRUCTURE THEN HAVING THE OUTER LAYERS ATTACHED THERETO. COMPARED TO THE COMPOSITE SANDWICH PANEL CONSTRUCTION HAVING NO Z-SHAPED REINFORCING ELEMENTS IN SAID CORE, THE PRESENT CONSTRUCTION HAS SUBSTANTIALLY IMPROVED STRENGTH.

L Niebylski

Papers

Composite sandwich panel type construction