The invention relates to a method for producing a metal foam of at least one first metal that contains the main constituent Mg, Al, Pb, Au, Zn, Ti or Fe in a quantity of at least approximately 80 wt. % in relation to the quantity of the at least one first metal, said method comprising the following steps: (I) providing a semi-finished product comprising a foamable mixture that comprises the at least one first metal and at least one foaming agent, (II) submerging the semi-finished product in a heatable bath comprising a liquid, and (III) heating the semi-finished product in the bath in order to foam the foamable mixture by removing gas from the at least one foaming agent for forming the metal foam. The invention also relates to a metal foam, to a composite material that can be obtained by the method, and to a component comprising the metal foam and/or the composite material.

A method of making a light weight component is provided. The method including the steps of: forming a metallic foam core into a desired configuration; and applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam core adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core; and securing an inlet fitting and an outlet fitting to the housing, wherein a thermal management fluid path for the internal component into and out of the housing is provided by the inlet fitting and the outlet fitting.

A method of making a light weight component is provided. The method including the steps of: forming a metallic foam core into a desired configuration; applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration; forming an inlet opening and an outlet opening in the external metallic shell in order to provide a fluid path through the metallic foam core; and injecting a thermoplastic material into the metallic foam core via the inlet opening.

A method of making a light weight component including the steps of: forming a metallic foam core into a desired configuration; applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration; forming an inlet opening and an outlet opening in the external metallic shell in order to provide a fluid path through the metallic foam core; and injecting a thermoplastic material into the metallic foam core via the inlet opening.

Structural metal-matrix composites (MMC) comprising a foam matrix material infiltrated with a binder material, where the binder material binds the foam matrix material to a structural element of a tool, thereby enhancing three-dimensional reinforcement of the tool. In some instances, the structural element is a portion of a wellbore tool or a bit body, such that portions of such tools or bit bodies are composed of the structural MMC. The foam matrix material may be composed of a metallic foam, a ceramic foam, and any combination thereof.

A method of making a light weight component is provided. The method including the steps of: forming a metallic foam core into a desired configuration; inserting a pre-machined component into an opening in the metallic foam core; applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration and after the pre-machined component has been inserted into the metallic foam core; introducing an acid into an internal cavity defined by the external metallic shell; dissolving the metallic foam core; and removing the dissolved metallic foam core from the internal cavity, wherein the component and the external metallic shell are resistant to the acid.

A method of making a light weight component is provided. The method including the steps of: forming a metallic foam core into a desired configuration; inserting a pre-machined component into an opening in the metallic foam core; applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration and after the pre-machined component has been inserted into the metallic foam core; introducing an acid into an internal cavity defined by the external metallic shell; dissolving the metallic foam core; and removing the dissolved metallic foam core from the internal cavity, wherein the component and the external metallic shell are resistant to the acid.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; and applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core.

Methods for manufacturing a metal foam and a metal foam reinforced back plate may be used to provide high-strength and low weight structural elements in portable information handling systems. A method for manufacturing a metal foam may include selectively adding iridium oxide and ceramic particulate to a light-metal allow to create desired mechanical properties of the metal foam.