Patent ID: 6090232
Filing Date: 2000-07-18
Classification: B22F,Y10T

Abstract:
A method for forming a shaped component comprising:forming a composite of metal foam material from a metal powder mixed with a blowing agent;providing a solid metal body;pressing one side of said solid metal body against one side of said composite;effecting a bond between said one side of said solid metal body and said one side of said composite as a result of said pressing to thereby form a generally flat semi-finished product;shaping said semi-finished product into a desired configuration in which said solid metal body has a shaped external surface conforming to said desired configuration, said shaped external surface having a contour portion having an angle of less than 180 degrees;maintaining said bond between said one side of said metal body and said one side of said composite during and after completion of said shaping step;providing a first mold surface having a configuration conforming to the configuration of said shaped external surface of said solid metal body;placing said shaped external surface of said solid metal body on said first mold surface in conforming engagement with said first mold surface;providing a second forming mold surface having a configuration conforming generally to the configuration of said shaped external surface of said solid metal body;positioning said second mold surface in a superimposed and generally parallel relationship with said first mold surface;said positioning step including positioning said second mold surface in a position spaced from said composite;foaming said composite of metal foam material;expanding said composite of foam material in a direction away from said one side of said solid metal body while maintaining a conforming relationship between said shaped external surface of said solid metal body and said first mold surface;utilizing said second mold surface to limit the expansion of said composite by effecting engagement between said composite and said second mold surface to thereby obtain an expanded structure of constant thickness; andremoving said expanded structure from said first and second mold surfaces to thereby obtain a finished product having a first outer boundary formed by said shaped external surface of said solid metal body and a second outer boundary formed by said composite and conforming generally to the configuration of said second mold surface and in which the expanded composite of metal foam material is bonded to the solid metal body and the composite of metal foam material has a uniform integrity of cell structure.