Production Process

Stabilized Aluminum Foam Process

Liquid metals cannot easily be foamed by bubbling air through them. Drainage of the liquid down the walls of the bubbles occurs too quickly and the bubbles collapse. However, if a small percentage of insoluble particles are added to the melt, the flow of the liquid metal is impeded sufficiently to stabilize the bubbles. This is the theory behind Cymat Stabilized Aluminum Foam.
 

Production Route

The Cymat process for manufacturing SAF involves 4 basic steps:

  • Melting the desired aluminum alloy
  • Transferring the molten material to the foaming box
  • Injecting gas to form liquid foam
  • Solidifying the liquid foam into desired shape


This process has the advantages of being scalable and portable, as well as being low in capital cost.
 

3-D Casting Production

3-D shapes can be made by low pressure casting. This method uses a metal matrix composite as the base material.
 

Low Pressure Casting

Cymat's Low Pressure Casting is similar to the aluminum low pressure casting process, which is commonly used to make aluminum wheels. Cymat's process involves injection of SAF into a mould. The pressure of injection is controlled so that it is sufficient to fill the mold precisely, but it is not so high that it collapses the unique cell structure of SAF. This technology will enable Cymat to make foam core parts, thereby reducing the cost, complexity and weight of the parts substantially. The density range this process is capable of is 15-25%.