Alcoa Inc.

J Daniel Bryant

Larry F Wieserman

Andrew J Hinkle

Joseph R Genito

Mark D Crowley

Jacob A Kallivayalil

Deborah Murphy Wilhelmy

William E Boren, Jr

Narsimhan Raghunathan

A method for producing an aluminum foam product wherein reactive gas producing particles are introduced into an aluminum alloy melt under controlled conditions and subjected to agitation to induce the production of foam-stabilizing by-products, and, under certain conditions, the production of gases used to produce the molten metal foam itself. Foam products produced through this method have intrinsically formed metal oxides and other solid particles dispersed therein and are devoid of the large extrinsically added stabilizing ceramic additions traditionally used in the production of aluminum foams. The invention claims a rapid, single step method for producing an inoculated, foamable melt using low cost precursor materials.

Method for producing foamed aluminum products by use of selected carbonate decomposition products

A method of operating a twin wheel conform metal extrusion device or a cladding extrusion device for producing a composite of an extruded metal shell bonded to a metal foam core. A metal feedstock is extruded through an extrusion die defining a cavity housing a hollow extrusion mandrel to produce a metal shell. Liquid foam of a second metal is simultaneously delivered through the hollow mandrel bore such that the foam exiting the axial bore is metallurgically bonded to the metal extruded through the cavity.

Coextruded products of aluminum foam and skin material

This invention provides a method and apparatus for casting, hot rolling and annealing of non-heat treatable aluminum alloys which comprises continuously casting, hot rolling and, in-line with the hot rolling line, heating the aluminum sheet using infrared heat. The infrared heating system uses a control to assure that the aluminum alloy is heated to the proper temperature based on one or a number of process variables, such as hot rolling exit temperature, hot rolled product exit rate in terms of speed and product dimensions, and sheet temperature at the exit of the infrared heater. Variations in the infrared heating temperature can be tolerated in the product without deviating from target mechanical properties.

Method and apparatus for casting, hot rolling and annealing non-heat treatment aluminum alloys

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Murrysville, PA, United States of America

J Daniel Bryant