Syntactic metal matrix materials and methods

A deformable syntactic metal foam composite formed of metal-coated microballoons and a metal matrix material that have been sintered together;

• said metal-coated microballoons include ceramic microballoons that are coated with a coating of metal material;
• said metal matrix material prior to being subjected to sintering includes metal powder and a clean burning binder that is formulated to be burnt off during said sintering;
• said ceramic microballoons have an average particle size of 1 to 500 microns;
• said ceramic microballoon constitutes a greater weight percent of said metal-coated microballoon than said coating of metal material on said metal-coated microballoon;
• said coating of metal material is formed on said ceramic microballoon prior to combining said metal-coated microballoons with said metal matrix material;
• said deformable syntactic metal foam composite includes a solid discontinuous phase comprised of reinforcing material.

A deformable syntactic metal foam composite formed of metal-coated microballoons and a metal matrix material that have been sintered together;

• said metal-coated microballoons include microballoons that are coated with a coating of metal material;
• said metal matrix material prior to being subjected to sintering includes metal powder and a clean burning binder that is formulated to be burnt off during said sintering;
• said microballoons have an average particle size of 1 to 500 microns;
• said microballoon constitute a greater weight percent of said metal-coated microballoon than said coating of metal material on said metal-coated microballoon;
• said coating of metal material is formed on said microballoon prior to combining said metal-coated microballoons with said metal matrix material;
• said metal-coated microballoon is a glass microballoon coated with aluminum;
• said glass microballoon has a particle size of 10-85 microns and a particle density of about 0.3 grams per cubic centimeter.

A deformable syntactic metal foam composite that is substantially free of non-syntactic porosity;

• said deformable syntactic metal foam composite includes metal-coated microballoons and a metal matrix material;
• said metal-coated microballoons have been at least partially secured together by a sintering process;
• each of said metal-coated microballoons includes a microballoon and a metal coating;
• each of said microballoons constitutes a greater weight percent of said metal-coated microballoon than said coating of metal material on said metal-coated microballoon prior to said sintering together of said metal-coated microballoons;
• said metal coating on each of said microballoons is formed by chemical vapor deposition or by immersion in a metal slurry prior to said sintering together of said metal-coated microballoons;
• at least a portion of said metal matrix material is formed from a metal additive and said metal coating on said metal-coated microballoon;
• said metal coated microballoon is a glass microballoon coated with aluminum;
• said glass microballoon has a particle size of 10-85 microns and a particle density of about 0.3 grams per cubic centimeter;
• said metal matrix material includes aluminum.

A deformable syntactic metal foam composite that is substantially free of non-syntactic porosity;

• said deformable syntactic metal foam composite includes metal-coated microballoons and a metal matrix material;
• said metal-coated microballoons have been at least partially secured together by a sintering process;
• each of said metal-coated microballoons includes a microballoon and a metal coating;
• each of said microballoons constitutes a greater weight percent of said metal-coated microballoon than said coating of metal material on said metal-coated microballoon prior to said sintering together of said metal-coated microballoons;
• said metal coating on each of said microballoons is formed by chemical vapor deposition or by immersion in a metal slurry prior to said sintering together of said metal-coated microballoons;
• at least a portion of said metal matrix material is formed from a metal additive and said metal coating on said metal-coated microballoon;
• said metal coated microballoon is a metal silicate ceramic microballoon coated with aluminum;
• said metal silicate ceramic microballoon has a particle size of 5-180 microns and a particle density of at least 0.6 grams per cubic centimeter;
• said metal matrix material includes aluminum.

A deformable syntactic metal foam composite that is substantially free of non-syntactic porosity;

• said deformable syntactic metal foam composite includes metal-coated microballoons and a metal matrix material;
• said metal-coated microballoons have been at least partially secured together by a sintering process;
• each of said metal-coated microballoons includes a microballoon and a metal coating;
• each of said microballoons constitutes a greater weight percent of said metal-coated microballoon than said coating of metal material on said metal-coated microballoon prior to said sintering together of said metal-coated microballoons;
• said metal coating on each of said microballoons is formed by chemical vapor deposition or by immersion in a metal slurry prior to said sintering together of said metal-coated microballoons;
• at least a portion of said metal matrix material is formed from a metal additive and said metal coating on said metal-coated microballoon;
• said metal coated microballoon is a carbon microballoon coated with titanium;
• said metal carbon microballoon has a particle size of 5-180 microns;
• said metal matrix material includes titanium.

A deformable syntactic metal foam composite that is substantially free of non-syntactic porosity;

• said deformable syntactic metal foam composite includes metal-coated microballoons and a metal matrix material;
• said metal-coated microballoons have been at least partially secured together by a sintering process;
• each of said metal-coated microballoons includes a ceramic microballoon and a metal coating;
• each of said ceramic microballoons for each of said metal-coated microballoons has an average particle size of 5-180 microns;
• each of said ceramic microballoons constitutes a greater weight percent of said metal-coated microballoon than said coating of metal material on said metal-coated microballoon prior to said sintering together of said metal-coated microballoons;
• said metal coating on each of said ceramic microballoons is formed by chemical vapor deposition or by immersion in a metal slurry prior to said sintering together of said metal-coated microballoons;
• at least a portion of said metal matrix material is formed from a metal additive and said metal coating on said metal-coated microballoon;
• said ceramic microballoons include carbon microballoons, alumino-silicate microballoons, glass microballoons, graphite microballoons, metallic oxide microballoons, metallic carbide microballoons, metallic nitride microballoons, and/or metal silicate microballoons;
• said metal matrix material includes aluminum, titanium, iron, nickel, copper, cobalt, and/or magnesium;
• said deformable syntactic metal foam composite includes a solid discontinuous phase comprised of reinforcing material.