Patent ID: 6464933
Filing Date: 2002-10-15
Classification: B22F

Abstract:
A method of fabricating a foamed metal structure using a powder supply of metal particles, comprising:(a) introducing the supply of metallic powder particles, along with foaming agent particles, into a propellant gas preheated to a temperature in the range of 300-500Â° F. and pressurized to at least 350 psi, to form a gas/particle mixture; (b) projecting said mixture at least at a critical particle velocity onto a metallic substrate to create a deposit of pressure-welded metal particles containing said admixed foaming agent; and (c) concurrently or subsequently subjecting at least the coating on said substrate to a thermal excursion effective to activate expansion of said foaming agent while softening the metal particles for plastic deformation under the influence of the expanding gases.