Cellarized Metal and Method of Making US 3,297,431
US 3,297,431

Cellarized Metal and Method of Making

Metal foams are interesting, engineered materials. Like other foams the structure is largely air. The large number of cell walls around the bubbles provides good energy absorption properties. However, in most metallic systems the bubbles will collapse during solidification from the melt. Early approaches used exotic, high viscosity alloys.

Here, a stabilizing powder is added to the melt to increase viscosity and maintain a foam structure through solidification. In one example, the powder is said to be C, Si or Fe. It is indicated that the powder should be wettable by the metallic system. Further, the powder should be stable with respect to the molten metal. Various particle sizes and weight fractions are presented. Preferably, the amount of powder does not exceed 50% by weight. The technology is agnostic to the foaming approach. In one example, H2 is dissolved into a Mg melt. Foam is created when the surrounding pressure is lowered, and the gas is liberated or evolved from the metal.

Standard Oil Company

Priority date:

John A. Ridgway


Independent Claims:
Method – 1, 2, 3 and 7
Apparatus – 5

Patents in Field:
US 11,021,120 – Uniform Deceleration Unit

US 5,281,251 – Process for shape casting of particle stabilized metal foam

EP 2044230 – Process for the production of metal foams

Resource Links:

The 2021 Motor Bella Neé Detroit Auto Show Goes Full Wet Blanket

Duocel (TM) Aluminum Foam

Foamed Aluminum

Analyst Comment:
Metal foams show utility for absorbing mechanical energy such as pressure waves and sound. There is also discussion of EM shielding. Extending this thought one could see research into pore size and density dependancy.

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Technology Tree

Where am I? The first metal foams were based on high viscosity “exotic” metals. Moving to lower viscosity common metals requires an approach for cell stabilization, such as particles.


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