Provided in one embodiment is a method of making use of foams as a processing aid or to improve the properties of bulk-solidifying amorphous alloy materials. Other embodiments include the bulk-solidifying amorphous alloy/foam composite materials made in accordance with the methods.

A method of freeze-drying comprising rapidly freezing either liquid or supercritical carbon dioxide in and around a material having pores at a rate of at least 0.2 C./min to limit the size of crystals formed from the carbon dioxide so as to avoid the formation of gas bubbles and damage to the pores and exposure of the material to gas-liquid interfaces. During freezing a solid layer primarily of solid carbon dioxide is formed on and surrounding the material by transferring heat with a cryogenic liquid circulating about the material. This solid layer protects the material from gas-liquid interfaces and surface tension before decreasing pressure about the material by venting carbon dioxide.

Foamable semifinished product (1) in the form of granules produced from the metal alloy and the foam agent is inserted into the cavity of the closable mould (2) and the liquid (3) with the density that is higher than the apparent (or bulk) density of the resulting foam is led to it. The liquid has a temperature which is higher than the temperature of the melting of the metal alloy; the transfer of the heat to the particles of the foamable semifinished product (1) takes place; it subsequently expands, whereby it is supported by the liquid (3). During the expansion at least part of the liquid (3) is pushed by the expansion itself out of the mould (2) through the opening. The liquid (3) allows the regulation of the pressure of the environment of the foam agent, too, which helps to set exactly the moment of expansion. The metal melt can be advantageously used as liquid (3). The melt can partially remain in the mould (2) so the hybrid structure of the component is created. The new method makes the foaming significantly quicker, it secures the homogeneity of the metal foam, simplifies the moulds and diminishes the energy demands for the whole process.

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.

A method to manufacture reticulated metal foam via a dual investment, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then applying an outer mold to the encapsulated precursor as a shell-mold.

A process for assembling a device including first and second parts made of first and second materials, respectively, and a third part made of a third material that acts as an intermediate part enabling the assembling, the process including: providing a preform made from an at least partially amorphous metal material capable of increasing its volume under temperature and pressure conditions; placing the first and second parts with the preform between two cavity plates having, the negative shape of the device; heating the assembly to a temperature between the glass transition temperature and the crystallization temperature of the preform to enable, at latest during the heating, the preform to be in a form of a foam and enable expansion of the preform to fill the negative shape of the device and form the third part; cooling the assembly to solidify the preform and separate the device from the cavity plates.

A device including a first portion made of a first material and a second portion made of a second material, the second part extends from one of faces of the first portion and is made of an amorphous material.

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investing a precursor with a diluted pre-investment ceramic plaster to encapsulate the precursor; and investing the encapsulated precursor with a ceramic plaster within an mold of a varied cross-section. A varied cross-section mold includes a mold thickness adjacent to an outer periphery of a pattern at a top of the varied cross-section mold is between 200-500% a thickness between the outer periphery of the pattern at a base of the varied cross-section mold. A varied cross-section mold includes a trapezoidal prism shape with a pour cone in a top, the top larger than the base.

A method for producing a structural component having a foam structure formed by foaming a foamable material, includes the following steps: additively building a receiving component that reproduces the outer geometry of the structural component to be produced at least in some sections, in particular completely, and having a receiving space for receiving foamable material; introducing at least one foamable material into the receiving space of the receiving component; and carrying out at least one measure for foaming the foamable material introduced into the receiving space of the receiving component so as to form the foam structure.

A method to manufacture reticulated metal foam via a dual investment solid mold, includes pre-investment of a precursor with a diluted pre-investment ceramic plaster then investing the encapsulated precursor with a ceramic plaster.