Open-porous metal foam body and a method for fabricating the same

Patent metadata

Field	Value
Publication number	US-9346240-B2
Application number	US-201314011939-A
Country	US
Kind code	B2
Filing date	Aug 28, 2013
Priority date	Aug 10, 2010
Publication date	May 24, 2016
Grant date	May 24, 2016

Abstract

Disclosed are an open-porous metal foam and a method for manufacturing the same. An open-porous metal foam according to an exemplary embodiment of the present invention is made of an iron-based alloy including 15 wt % or more of chrome and 5 wt % or more of aluminum. The open-porous metal foam is a semi-product that is formed of iron or the iron-based alloy that does not include chrome and aluminum or includes a smaller amount of chrome and aluminum in the powder when manufacturing, and the surface and the open pore thereof are uniformly coated with the powder of the iron-chrome-aluminum alloy and the organic binding agent. When heat treatment is performed under a reduction atmosphere, sintering is performed. In this case, the metal foam body that is formed of the iron-chrome-aluminum alloy is obtained by compensating concentrations of alloy elements between the semi-product and the powder by diffusion, and a content of chrome and aluminum in the metal foam is smaller than a content of chrome and aluminum included in a starting alloy of the used powder.

First claim

What is claimed is:

1. A method for manufacturing an open-porous metal foam, comprising:
providing a semi-product that does not include chromium and aluminum or include a smaller amount than an amount in powder of an iron-chromium-aluminum alloy and is formed of iron or an iron-based alloy;
uniformly coating a surface and an opened pore of the semi-product that is formed of the iron or the iron-based alloy with the powder of the iron-chromium-aluminum alloy and an organic binding agent;
discharging excessive organic binding agent by heat treating the semi-product that is formed of the coated iron or iron-based alloy under a reducing atmosphere at a temperature of 300 to 600° C.; and
sintering the semi-product that is formed of the iron or the iron-based alloy from which the excessive organic binding agent are discharged at the temperature of 900° C. or more.

2. The method of claim 1 , wherein:
the semi-product is a foam which is formed by depositing the iron or the iron-based alloy on an organic open-porous foam by an electroplating manner.

3. The method of claim 2 , wherein:
an average particle size of the powder is 20 μm to 50 μm.

4. The method of claim 2 , wherein:
heated at a heating speed of the sintering is 5 K/min to a temperature of 1300° C., and the temperature is maintained for at least 30 min.

5. The method of claim 1 , wherein:
an average particle size of the powder is 20 μm to 50 μm.

6. The method of claim 1 , wherein:
when the sintering is performed, a metal foam of the iron-chromium-aluminum alloy is formed by compensating concentrations of alloy elements between the semi-product and the powder by diffusion, and a content of chromium and aluminum in the metal foam is smaller than a content of chromium and aluminum included in a starting alloy of the used powder.

7. The method of claim 6 , wherein:
a heating speed of the sintering is 5 K/min to a temperature of 1300° C., and the temperature is maintained for at least 30 min.

8. The method of claim 1 , wherein:
heated at a heating speed of the sintering is 5 K/min to a temperature of 1300° C., and the temperature is maintained for at least 30 min.

Assignees

• Alantum
• Fraunhofer Ges Forschung
• Fraunhofer Ges Forschung

Inventors

• Walther Gunnar
• Klöden Burghardt
• Böhm Juliane
• Büttner Tilo
• Weissgärber Thomas
• Kieback Bernd
• Boden Arne
• Böhm Hans-Dietrich
• Kim Hyuntae
• Choi James
• Jang Myungjoon
• Böhm Alexander
• Fröhlich Stefan
• Dölling Winfried

Classifications

• C22C38/06 Primary

  containing aluminium · CPC title

• B22F3/11

  Making porous workpieces or articles · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F3/1146

  After-treatment maintaining the porosity (B22F3/114 takes precedence) · CPC title

• Y10T428/12479

  Porous [e.g., foamed, spongy, cracked, etc.] · CPC title