Method for Manufacturing Porous Metal Body, and Porous Metal Body

Patent metadata

Field	Value
Publication number	US-2023374627-A1
Application number	US-202118029943-A
Country	US
Kind code	A1
Filing date	Sep 16, 2021
Priority date	Oct 5, 2020
Publication date	Nov 23, 2023
Grant date	—

Abstract

A method for manufacturing a porous metal body according to the present invention is a method for manufacturing a sheet-shaped porous metal body 4 a containing titanium by sintering a titanium-containing powder 4 by heating it on a forming surface 2 of a forming die 1 , the method including: an area setting step of setting, on the forming surface 2 of the forming die 1 , an adhesion area Aa where it is located on an outer edge side of the forming surface 2 and the titanium-containing powder 4 adheres during sintering without a releasing layer 3 , and an easily releasable area Ar where a releasing layer 3 is formed; after the area setting step, a powder deposition step of depositing the titanium-containing powder 4 in a dry process on the forming surface 2 ; and after the powder deposition step, a powder sintering step of sintering the titanium-containing powder 4 on the forming surface 2 while heating the titanium-containing powder 4 at a temperature of 950° C. or more on the forming surface 2 and allowing the titanium-containing powder 4 located on the adhesion area Aa to adhere to the adhesion area Aa.

First claim

1 . A method for manufacturing a sheet-shaped porous metal body containing titanium by sintering a titanium-containing powder by heating the titanium-containing powder on a forming surface of a forming die, the method comprising:
an area setting step of setting, on the forming surface of the forming die, an adhesion area located on an outer edge side of the forming surface and the titanium-containing powder adheres during sintering without a releasing layer, and an easily releasable area where a releasing layer is formed; after the area setting step, a powder deposition step of depositing the titanium-containing powder in a dry process on the forming surface; and after the powder deposition step, a powder sintering step of sintering the titanium-containing powder on the forming surface while heating the titanium-containing powder at a temperature of 950° C. or more on the forming surface and allowing the titanium-containing powder located on the adhesion area to adhere to the adhesion area.

2 . The method according to claim 1 , wherein the titanium-containing powder has an average circularity of 0.93 or less.

3 . The method according to claim 1 , wherein the forming die comprises at least one selected from the group consisting of carbon, quartz, graphite, magnesia, calcia, zirconia, and yttria.

4 . The method according to claim 1 , wherein in the area setting step, the releasing layer is formed by a releasing agent containing boron nitride and/or titanium boride.

5 . The method according to claim 1 , wherein the titanium-containing powder has a 90% particle size D90 of 15 μm to 50 μm.

6 . The method according to claim 1 , wherein a ratio of a surface area of the forming surface of the forming die on which the titanium-containing powder is deposited in the powder deposition step to a surface area of the easily releasable area is 1.05 to 1.50.

7 . The method according to claim 1 , wherein in the powder deposition step, the surface area of the forming surface of the forming die on which the titanium-containing powder is deposited is 64 cm 2 or more.

8 . The method according to claim 1 , wherein the titanium-containing powder has a titanium content of 75% by mass or more.

9 . A porous metal body comprising titanium, wherein the porous body has a sheet shape with a thickness of 0.2 mm to 1.0 mm, and wherein the porous body has a porosity of 20% to 65%, and a bending strength of 190 MPa or more.

10 . The porous metal body according to claim 9 , wherein the porous metal body has a titanium content of 75% by mass or more.

11 . The porous metal body according to claim 9 , wherein,
when a sample of the porous metal body is placed on a flat surface and a maximum height from a position of the flat surface to a highest position on a surface of the sample is measured in a thickness direction, the maximum height is 3 times or less a thickness of the porous metal body when the thickness is 0.5 mm or more, or the maximum height is 1.5 mm or less when the thickness of the porous metal body is less than 0.5 mm.

Assignees

• Toho Titanium Co Ltd
• Toyota Motor Co Ltd

Inventors

• Tsumagari Shougo
• Inoue Yosuke
• Kawai Hiroyuki

Classifications

• C22C1/0458 Primary

  Alloys based on titanium, zirconium or hafnium · CPC title

• C22C14/00

  Alloys based on titanium · CPC title

• B22F3/11 Primary

  Making porous workpieces or articles · CPC title

• C22C1/08

  Alloys with open or closed pores · CPC title

• Y02E10/542

  Dye sensitized solar cells · CPC title