EP2045029A1 - Fabrication of aluminium foams by the impregnation of polyurethane foam with a slurry comprising aluminium and salt - Google Patents

Fabrication of aluminium foams by the impregnation of polyurethane foam with a slurry comprising aluminium and salt Download PDF

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Publication number
EP2045029A1
EP2045029A1 EP08386018A EP08386018A EP2045029A1 EP 2045029 A1 EP2045029 A1 EP 2045029A1 EP 08386018 A EP08386018 A EP 08386018A EP 08386018 A EP08386018 A EP 08386018A EP 2045029 A1 EP2045029 A1 EP 2045029A1
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EP
European Patent Office
Prior art keywords
slurry
foams
impregnation
aluminium
fabrication
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP08386018A
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German (de)
French (fr)
Other versions
EP2045029B1 (en
Inventor
Dimitrios Tsipas
Mohamad Hidar Omar
Dimitrios Papadopoulos
Sofia Tsipas
Nikolaos Michailidis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Michailidis Nikolaos
Omar Mohamad Hidar
PAPADOPOULOS, DIMITRIOS
TSIPAS, DIMITRIOS
TSIPAS, SOFIA
Aristotle University of Thessaloniki ELKE Research Committee
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Aristotle University of Thessaloniki
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Application filed by Aristotle University of Thessaloniki filed Critical Aristotle University of Thessaloniki
Publication of EP2045029A1 publication Critical patent/EP2045029A1/en
Application granted granted Critical
Publication of EP2045029B1 publication Critical patent/EP2045029B1/en
Not-in-force legal-status Critical Current
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1137—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers by coating porous removable preforms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy

Definitions

  • the current invention refers to a fabrication method of porous materials and similar structures. More specifically the invention alms at the improvement of the fabrication method of Al and its alloys with porous structures under conditions of atmospheric pressure and leading to final products with improved structures and properties.
  • Porous materials are known in materials technology as foams or sponges and these materials are fabricated using different methods.
  • the advanced materials with porous structures can be found in the group of polymeric, metallic, ceramic and composite materials.
  • porous structured materials foams or sponges which from now on we will refer as porous materials consist of a group of cells open or closed in structure which leads to much lower density compared to bulk materials.
  • the present invention reports the fabrication of open cell metal foams using organic templates of known 3D geometry.
  • the process involves the step of impregnation of the organic template material with slurry containing alcohol, salts, and Al metal or alloy powder.
  • the impregnated organic template is left to dry at ambient temperature for 24 hours and the heated at temperature between 215 -500°C for 3,5-5 hours so as to obtain the evaporation of the organic template.
  • the final step includes sintering in an inert atmosphere at temperatures between 500°C-525°C for 0,5-1 hr aiming at producing structures with improved properties.
  • Al powder 4 microns average size 97% by weight Al powder 4 microns average size is mixed with 3%AlCl 3 .
  • the above mixture is added to ethanol in the ration 1/40 by volume creating slurry.
  • the template organic material foam is impregnated with the above slurry and left to dry at ambient temperature for 24 hrs.
  • the cell sizes of the organic template foam are selected so as to give the desired size of pores in our final metal foam product.
  • the slurry Impregnated material is placed in a furnace at temperature between 215-500°C for 3,5-5 hrs and using an inert (Ar 2 or N 2 ) atmosphere so as to limit the formation of oxides.
  • the material is then cooled to room temperature and the final stage involves sintering the metal foam structure in the temperature range 500-525°C for 0.5-1 hr, in an inert atmosphere.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

Fabrication of 3D open cell metal foams with the method of impregnation of polymeric foams with slurries containing metal powders and one or more salts. The process includes drying at ambient temperature of the template foam being impregnated with the slurry, heat treatment to produce evaporation of the template foam followed by final sintering at the appropriate temperature and in an inert atmosphere in order to produce structures with improved properties.

Description

  • The current invention refers to a fabrication method of porous materials and similar structures. More specifically the invention alms at the improvement of the fabrication method of Al and its alloys with porous structures under conditions of atmospheric pressure and leading to final products with improved structures and properties.
  • Porous materials are known in materials technology as foams or sponges and these materials are fabricated using different methods.
  • The advanced materials with porous structures can be found in the group of polymeric, metallic, ceramic and composite materials.
  • The porous structured materials foams or sponges which from now on we will refer as porous materials consist of a group of cells open or closed in structure which leads to much lower density compared to bulk materials.
  • Many different methods have been used for fabricating these porous materials. These methods include liquid metallurgy or powder metallurgy and the pore structure shows a random distribution. This structure is the result of substances (materials) that are added into the mixture and decompose when thermally treated or are produced by the direct introduction of inert gas bubbles into the liquid metal before solidification.
  • In US Patent No 3111.396 a fabrication method for producing porous materials is presented which includes various consecutive steps in which a solid organic structure is immersed in liquid metal dried and heated in an inert atmosphere until the solid organic template evaporates.
  • In us patent No 4973.385 a process is given in which gas bubbles are introduced into the liquid metal to produce foaming followed by solidification and the formation of a porous structure.
  • In the Patent No 9731738 a process is described in which a solution containing alcohol resins, and metal powder is used to impregnate an organic template. The impregnated organic material is dried and heated under vacuum until the organic template is evaporated. The final stage involves sintering of the structure
  • The advantages of our proposed invention are its simplicity and low cost as it is executed under atmospheric conditions and using standard readily available equipment and its environmentally friendly.
  • In fig. 1 we present a photo showing the metal foam that was produced using the above described method.
  • The present invention reports the fabrication of open cell metal foams using organic templates of known 3D geometry. The process involves the step of impregnation of the organic template material with slurry containing alcohol, salts, and Al metal or alloy powder.
  • The impregnated organic template is left to dry at ambient temperature for 24 hours and the heated at temperature between 215 -500°C for 3,5-5 hours so as to obtain the evaporation of the organic template. The final step includes sintering in an inert atmosphere at temperatures between 500°C-525°C for 0,5-1 hr aiming at producing structures with improved properties.
    • Example
  • 97% by weight Al powder 4 microns average size is mixed with 3%AlCl3. The above mixture is added to ethanol in the ration 1/40 by volume creating slurry.
  • The template organic material foam is impregnated with the above slurry and left to dry at ambient temperature for 24 hrs. The cell sizes of the organic template foam are selected so as to give the desired size of pores in our final metal foam product.
  • The slurry Impregnated material is placed in a furnace at temperature between 215-500°C for 3,5-5 hrs and using an inert (Ar2 or N2) atmosphere so as to limit the formation of oxides. The material is then cooled to room temperature and the final stage involves sintering the metal foam structure in the temperature range 500-525°C for 0.5-1 hr, in an inert atmosphere.

Claims (7)

  1. A method of fabrication of Al and Al alloys foams which involves a selection of the appropriate organic template foams e.g. polyurethane with specific cell size and 3D geometry. Preparation of a slurry containing Al powder, salts (e.g. AlCl3) and organic material such as alcohol, ethanol, methanol etc. Impregnation of the organic template foam with the slurry drying at room temperature for 24 hour followed by heating between 215°-500°C for 3.5-5 hours in and inert atmosphere until all the organic material is evaporated followed by cooling to room temperature. The final stage involves sintering the structure at temperatures between 500-525°C for 0.5-1 hr in an inert atmosphere.
  2. In the claim 1 instead of Al powder Al Alloy powder can be used.
  3. In the claim 1 by salts we include all the halogen containing salts.
  4. In the claim 1 instead of ethanol for the slurry for mention other organic solutions can be used.
  5. In claim 1 the impregnation of the organic template can be executed by using other auxiliary methods or equipment including the use of vacuum.
  6. In claim 1 the thermal treatment can be done in a normal atmosphere.
  7. In claim 1 a fluidized bed system electric furnace can be used.
EP08386018A 2007-08-02 2008-07-31 Fabrication of aluminium foams by the impregnation of polyurethane foam with a slurry comprising aluminium and salt Not-in-force EP2045029B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GR20070100504A GR1006099B (en) 2007-08-02 2007-08-02 Production of three-dimensional, open-cell metallic sponges by impregnating a polyurethane foam and respective related materials with a thick mixture of metal powder and salts.

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
GR20070100504 Previously-Filed-Application 2007-08-02

Publications (2)

Publication Number Publication Date
EP2045029A1 true EP2045029A1 (en) 2009-04-08
EP2045029B1 EP2045029B1 (en) 2012-02-01

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Application Number Title Priority Date Filing Date
EP08386018A Not-in-force EP2045029B1 (en) 2007-08-02 2008-07-31 Fabrication of aluminium foams by the impregnation of polyurethane foam with a slurry comprising aluminium and salt

Country Status (4)

Country Link
EP (1) EP2045029B1 (en)
AT (1) ATE543595T1 (en)
ES (1) ES2382639T3 (en)
GR (1) GR1006099B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106475557A (en) * 2015-08-26 2017-03-08 精工爱普生株式会社 Three-dimensionally formed device, three-dimensionally formed method and three-dimensionally formed thing

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190015895A1 (en) * 2016-01-15 2019-01-17 University Of North Texas Method for Producing Textured Porous Metals

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3111396A (en) 1960-12-14 1963-11-19 Gen Electric Method of making a porous material
US3322535A (en) * 1965-06-01 1967-05-30 Mallory & Co Inc P R Addition agents for exothermic sintering processes
US4973385A (en) 1990-04-24 1990-11-27 Jean Ming Gwo Vacuum water drawing cylinder for making paper
WO1997031738A1 (en) 1996-02-27 1997-09-04 Astro Met, Inc. Porous materials and method for producing
WO2002066693A1 (en) * 2001-02-19 2002-08-29 Isotis N.V. Porous metals and metal coatings for implants

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3111396A (en) 1960-12-14 1963-11-19 Gen Electric Method of making a porous material
US3322535A (en) * 1965-06-01 1967-05-30 Mallory & Co Inc P R Addition agents for exothermic sintering processes
US4973385A (en) 1990-04-24 1990-11-27 Jean Ming Gwo Vacuum water drawing cylinder for making paper
WO1997031738A1 (en) 1996-02-27 1997-09-04 Astro Met, Inc. Porous materials and method for producing
WO2002066693A1 (en) * 2001-02-19 2002-08-29 Isotis N.V. Porous metals and metal coatings for implants

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106475557A (en) * 2015-08-26 2017-03-08 精工爱普生株式会社 Three-dimensionally formed device, three-dimensionally formed method and three-dimensionally formed thing

Also Published As

Publication number Publication date
ATE543595T1 (en) 2012-02-15
EP2045029B1 (en) 2012-02-01
ES2382639T3 (en) 2012-06-12
GR1006099B (en) 2008-10-09

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