Claims
- 1. In a method of operating a metal extrusion device for extruding a feedstock and having peripheral components for receiving feedstock, an extrusion die defining a cavity for receiving feedstock from the peripheral components, an extrusion mandrel mounted in the die and surrounded by the cavity, the extrusion mandrel having a terminal end and defining an axial bore, the improvement comprising:
extruding a first metal through the cavity and past the terminal end of the mandrel; and simultaneously delivering liquid foam of a second metal through the axial bore such that the foam exiting the terminal end of the axial bore is metallurgically bonded to the metal extruded through the cavity thereby producing a composite of an extruded metal shell bonded to a metal foam core.
- 2. The method of claim 1 wherein the first metal and the second metal are aluminum alloys.
- 3. The method of claim 2 wherein the first metal and the second metal are at a temperature of about 600 to about 650° C.
- 4. The method of claim 2 wherein the first metal is alloy AA 6063.
- 5. The method of claim 2 wherein the second metal comprises scrap aluminum alloys.
- 6. The method of claim 1 wherein the extruded metal shell is about 0.02 to about 0.5 inch thick.
- 7. The method of claim 1 wherein the first metal is in the form of a rod, a billet or a powder.
- 8. The method of claim 1 further comprising pumping the liquid metal foam into the axial bore.
- 9. The method of claim 1 wherein the peripheral components comprises a pair of feed wheels having peripheral feed grooves for receiving the feedstock and mounted for rotation about axes relative to the die to urge the feedstock into the cavity.
- 10. The method of claim 1 wherein the peripheral components comprises a pair of feed chambers for receiving the feedstock and pistons for urging the feedstock from the chambers into the cavity.
- 11. The method of claim 1 further comprising pumping the liquid metal foam into the axial bore.
- 12. An apparatus for producing a composite of an extruded metal shell bonded to a metal foam core comprising:
a metal extrusion device for extruding a feedstock and having peripheral components for receiving metal feedstock, an extrusion die defining a cavity for receiving metal feedstock from said peripheral components, an extrusion mandrel mounted in said die and surrounded by said cavity, said extrusion mandrel having a terminal end and defining an axial bore; a metal foam delivery member for supplying liquid metal foam through said axial bore, whereby providing metal feedstock to said peripheral components and extruding the metal through the cavity while providing metal foam through said axial bore causes the foam exiting the axial bore to metallurgically bind to the extruded metal to form a foam core covered by an extruded metal shell.
- 13. The apparatus of claim 12 wherein said foam delivery member further comprises a foam production member for producing liquid metal foam for delivery to said axial bore.
- 14. The apparatus of claim 12 wherein said foam delivery member further comprises a pump for delivering liquid metal foam to said axial bore.
- 15. The apparatus of claim 12 further comprising a sleeve extending from said foam delivery member to said axial bore terminal end and lining said axial bore to maintain the liquid foam spaced apart from the metal extrusion device
- 16. The apparatus of claim 12 wherein the peripheral components comprises a pair of feed wheels having peripheral feed grooves for receiving the feedstock and mounted for rotation about axes relative to the die to urge the feedstock into the cavity.
- 17. The apparatus of claim 12 wherein the peripheral components comprises a pair of feed chambers for receiving the feedstock and pistons for urging the feedstock from the chambers into the cavity
- 18. A composite product comprising an extruded metal shell metallurgically bonded to a metal foam core made according to the method of claim 1.
- 19. The composite product of claim 17 wherein the first metal and the second metal are aluminum alloys.
- 20. The composite product of claim 17 wherein the extruded metal shell is about 0.02 to about 0.5 inch thick.
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/310,675 filed Aug. 7, 2001 entitled “Coextruded Products of Aluminum Foam and Skin Material”.
Provisional Applications (1)
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Number |
Date |
Country |
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60310675 |
Aug 2001 |
US |