| US 7,452,402 B2 | ||
| Method for producing foamed aluminum products by use of selected carbonate decomposition products | ||
| J. Daniel Bryant, Murrysville, Pa. (US); Jacob A. Kallivayalil, Pittsburgh, Pa. (US); Mark D. Crowley, Pittsburgh, Pa. (US); Joseph R. Genito, Lower Burrell, Pa. (US); Larry F. Wieserman, Apollo, Pa. (US); Deborah Murphy Wilhelmy, Greensburgh, Pa. (US); and William E. Boren, Jr., Export, Pa. (US) | ||
| Assigned to Alcoa Inc., Pittsburgh, Pa. (US) | ||
| Filed on Apr. 29, 2005, as Appl. No. 11/119,002. | ||
| Prior Publication US 2006/0243094 A1, Nov. 02, 2006 | ||
| Int. Cl. C22B 21/06 (2006.01) | ||
| U.S. Cl. 75—684 | 18 Claims |
| 1. A method of making an aluminum foam product comprising:
adding reactive gas producing particles to a molten aluminum alloy at a temperature that is above the decomposition temperature
of the reactive gas producing particles so that, at least a portion of the reactive gas producing particles produce reactive
gas of carbon dioxide;
reacting the carbon dioxide with the molten aluminum alloy at a sufficient melt temperature of the alloy, sufficient ratio
of the reactive gas producing particles to the molten aluminum alloy, sufficient residence time and sufficient particle size
of the reactive gas producing particles so as to produce at least Al2O3,CO and a foamable suspension, wherein the foamable suspension is resistant to coalensense and drainage;
adding a chemical foaming agent to the foamable suspension;
mixing the foamable suspension with the chemical foaming agent to form an inoculated foamable suspension;
foaming the inoculated foamable suspension; and
forming a foamed aluminum product.
|