Patent ID: 7402277

Claim:
A method of forming a metallic foam layer on a substrate comprising the following steps: providing a substrate for coating of a metallic foam; cold spraying a mixture of metal particles and a foaming agent onto said substrate to form a substrate coated with an unexpanded metallic layer; foam heat treating said substrate coated with an unexpanded metallic layer at a temperature above the decomposition temperature of said foaming agent for a time sufficient to form a heated substrate coated with an expanded metal foam layer; and cooling said heated substrate coated with an expanded metal foam layer to about ambient temperature to form a cooled substrate coated with an expanded metal foam layer, wherein said cooled substrate coated with an expanded metal foam layer comprises an integral part of downhole casings, pipelines, transfer lines, and flow lines used in oil and gas exploration, refinery and chemical process equipment for improved thermal management, mechanical damping resistance and fire barrier protection.