초록 ▼

A novel method of forming low density core metal parts by pressure bonding face sheets to a porous foam metal core and simultaneously densifying the core is disclosed. In particular, low density core aluminum and aluminum alloy parts can be formed according to the method of the invention. The method

A novel method of forming low density core metal parts by pressure bonding face sheets to a porous foam metal core and simultaneously densifying the core is disclosed. In particular, low density core aluminum and aluminum alloy parts can be formed according to the method of the invention. The method of forming low density core metal parts generally comprises the steps of providing a porous, foam metal core and simultaneously pressure bonding first and second solid metal face sheets directly to opposite sides of the core and densifying the core by applying heat and uniaxial forge pressure to the first and second face sheets and to the core for a predetermined period of time. The method of the invention can therefore produce LDC parts having a predetermined shape and density. Furthermore, the LDC parts are less subject to interfacial oxidation and delamination than conventional LDC parts made by brazing.

대표청구항 ▼

[ That which is claimed:] [14.] A method for forming low density core aluminum or aluminum alloy parts comprising:providing first and second solid metal face sheets having a shape such that at least one of said face sheets is non-planar and providing a porous, foam core having an original thickness

[ That which is claimed:] [14.] A method for forming low density core aluminum or aluminum alloy parts comprising:providing first and second solid metal face sheets having a shape such that at least one of said face sheets is non-planar and providing a porous, foam core having an original thickness and a shape which corresponds generally to the shape of the face sheets, the core and face sheets comprising a material selected from the group consisting of aluminum and aluminum alloys;removing oxides and other impurities from the face sheets and the core to thereby facilitate bonding therebetween; andsimultaneously pressure bonding first and second face sheets directly to opposite sides of the core and densifying the core to no more than about 50%, of the original thickness to, produce an aluminum or aluminum alloy part having a low density, porous core by applying heat at a temperature of between 350.degree. C. and 500.degree. C. and uniaxial forge pressure up to about 1 ksi to the first and second face sheets and to the core for between about 5 and 60 minutes.