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1. WO1998033621 - PROCEDE DE LIAGE PAR PRESSION ET DE DENSIFICATION PAR PRESSION POUR LA FABRICATION DE PIECES METALLIQUES A NOYAU DE FAIBLE DENSITE

Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

[ EN ]

CLAIMS :

1. A method for forming low density core metal parts comprising:
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 the core for a predetermined period of time.

2. The method according to Claim 1 wherein said providing step comprises providing a porous foam core comprising a material selected from the group consisting of aluminum and aluminum alloys.

3. The method according to Claim 1 wherein said step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises applying heat at a temperature of between about 350°C and 500 °C and pressure at up to about 1 ksi for between about 5 and 60 minutes.

4. The method according to Claim 2 wherein said step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises pressure bonding first and second face sheets formed of a material selected from the group consisting of aluminum and aluminum alloys.

5. The method according to Claim 1 wherein the core has an original thickness prior to the application of heat and pressure, and wherein the step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises densifying the core to no more than about 50% of the original thickness .

6. The method according to Claim 1 wherein said providing step comprises providing a core having a porosity of between about 75 and 95 percent .

7. The method according to Claim 6 wherein the step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises densifying the core to a porosity of between about 30 and 50 percent.

8. The method according to Claim 1 further comprising the step of removing oxides and other contaminants from the first and second face sheets prior to pressure bonding the face sheets to the core.

9. The method according to Claim 1 further comprising the step of removing oxides and other impurities from the core prior to pressure bonding the face sheets to the core.

10. The method according to Claim 1 wherein said step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises pressure bonding the face sheets to the core and densifying the core in a hot press evacuated to a pressure of less than about 10"6 torr.

11. The method according to Claim 1 wherein said step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises pressure bonding the face sheets to the core and densifying the core in a hot press in an inert
environment .

12. The method according to Claim 1 wherein said step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises vacuum bagging the face sheets and the core in a steel envelope, placing the steel envelope in a hot forge, and simultaneously pressure bonding the face sheets to the core and densifying the core in the hot forge.

13. The method according to Claim 1 wherein said step of simultaneously pressure bonding the face sheets to the core and densifying the core comprises providing a forming die having a predetermined shape and pressure bonding face sheets which correspond generally to the shape of the forming die to the core to form a low density core part having a predetermined shape.

14. A method for forming low density core aluminum or aluminum alloy parts comprising:
providing first and second solid metal face sheets having a predetermined shape 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; and
simultaneously 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 by applying heat at a temperature of between 350°C and 500°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.

15. A low density core metal part
comprising:
a porous, foam metal core;
a first solid metal face sheet pressure bonded directly to said core on one side thereof; and
a second solid metal face sheet pressure bonded directly to said core on a side opposite that of said first face sheet.

16. The part according to Claim 15 wherein the porous, foam metal core is formed of a material selected from the group consisting of aluminum and aluminum alloys.

17. The part according to Claim 16 wherein at least one of said first and second face sheets is formed of a material selected from the group consisting of aluminum and aluminum alloys.

18. The part according to Claim 16 wherein the porosity of said core is between about 30 and 50 percent.