Abstract Foamed metal surfaces can be contoured as desired by crushing the foam to the desired shape. For example, foamed aluminum to be shaped is placed in a jig and a shaping platen is gradually lowered into the surface of the foam. This process compresses the top cells of the foam to the depth of contouring. The crushed area remarkably conforms to the shape of the platen with little or no rounding, bending, or other untoward deformation in the original surface adjacent to where the crushing force was applied. Brittle, fragile, or frangible foams are not desired starting materials for the process. Efficacious aluminum foams are prepared from base metals having less than about 2 per cent silicon and optionally up to about 15 weight per cent of a metal selected from magnesium, copper, and zinc. The crushing force used for contouring can also be utilized to clad a lamination of metal foil or plastic film to the foam surface being treated.
A PROCESS FOR CHANGING THE CONFIGURATION OF A SURFACE OF A FOAMED ALUMINUM BODY AND CONTEMPORANEOUSLY BONDING AN INTEGRAL LAMINA TO THE SURFACE BEING ALTERED, SAID PROCESS COMPRISING SUBJECTING A SURFACE OF A FOAM OF AN ALUMINUM BASE METAL TO A COMPRESSIVE ACTION, SAID SURFACE BEING PITTED WITH CAVITIES FROM FOAM CELLS HAVING AN AVERAGE PORE SIZE OF FROM ABOUT 1/32 TO ABOUT 1/8 OF AN INCH AND BEING OVERLAID WITH A METAL FOIL OF PLASTIC FILM HAVING A THICKNESS OF FROM ABOUT 1/2 TO METAL 5 MILS, SAID COMPRESSIVE ACTION BEING A MECHANICAL FORCE AT LEAST SUFFICIENT TO OVERCOME THE COMPRESSIVE STRENGTH
Claim 2
Dependent Claim
103 words
A PROCESS FOR CHANGING THE CONFIGURATION OF A SURFACE OF A FOAMED ALUMINUM BODY AND CONTEMPORANEOUSLY BONDING AN INTEGRAL LAMINA TO THE SURFACE BEING ALTERED, SAID PROCESS COMPRISING SUBJECTING A SURFACE OF A FOAM OF AN ALUMINUM BASE METAL TO A COMPRESSIVE ACTION, SAID SURFACE BEING PITTED WITH CAVITIES FROM FOAM CELLS HAVING AN AVERAGE PORE SIZE OF FROM ABOUT 1/32 TO ABOUT 1/8 OF AN INCH AND BEING OVERLAID WITH A METAL FOIL OF PLASTIC FILM HAVING A THICKNESS OF FROM ABOUT 1/2 TO METAL 5 MILS, SAID COMPRESSIVE ACTION BEING A MECHANICAL FORCE AT LEAST SUFFICIENT TO OVERCOME THE COMPRESSIVE STRENGTH
Claim 3
Dependent Claim
11 words
The foamed aluminum body prepared bY the process of claim 1.