METAL FOAMS AND METHODS OF MANUFACTURE

• US 20180230590A1
• Filed: 04/16/2018
• Published: 08/16/2018
• Est. Priority Date: 11/20/2015
• Status: Active Grant

• Current Assignee: Fourte International Sdn. Bhd.
• Original Assignee: Fourte International Sdn. Bhd.
• Inventors: Farquhar, James J., Seah, Choon Ming
• Granted Patent: US 10,590,529 B2
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2201/20 Use of vacuum
• CPC Class Codes: B22F 2202/06 Use of electric fields
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/1121 by using decomposable, meltable or sublimatable fillers
• CPC Class Codes: B22F 3/1134 Inorganic fillers carbonaceous or paper filler B22F3/1121
• CPC Class Codes: B22F 3/24 After-treatment of workpieces or articles B22F3/1146 takes precedence
• CPC Class Codes: B22F 5/007 of moulds
• CPC Class Codes: B22F 7/002 of porous nature
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• CPC Class Codes: B22F 7/062 involving the connection or repairing of preformed parts
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: C22C 1/04 by powder metallurgy C22C1/08 takes precedence
• CPC Class Codes: C22C 1/08 Alloys with open or closed pores
• CPC Class Codes: C22C 2026/002 Carbon nanotubes
• CPC Class Codes: C23C 14/205 by cathodic sputtering
• CPC Class Codes: C23C 16/01 : on temporary substrates, e.g. substrates subsequently removed by etching
• CPC Class Codes: C23C 16/045 : Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/26 : Deposition of carbon only
• CPC Class Codes: C23C 16/545 : for coating elongated substrates
• CPC Class Codes: F28F 13/003 : by using permeable mass, perforated or porous materials F28F13/18 takes precedence
• CPC Class Codes: H01M 2004/021 : Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/0402 : Methods of deposition of the material
• CPC Class Codes: H01M 8/04216 : characterised by the choice for a specific material, e.g. carbon, hydride, absorbent
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

Embodiments of the present technology include metal foams and methods of manufacture. An example method of creating a porous metal foam includes mixing an amount of a metallic powder with an amount of sacrificial particles in a specified ratio to create a mixture; and applying pressure to the mixture that is sufficient to: compact the mixture; decompose or dissolve the sacrificial particles; and fuse the metallic powder into the porous metal foam.

Claims

1. A method of creating a porous metal foam, the method comprising:

mixing an amount of a metallic powder with an amount of sacrificial particles in a specified ratio to create a mixture; and

applying pressure to the mixture that is sufficient to;

compact the mixture;

decompose or dissolve the sacrificial particles; and

fuse the metallic powder into the porous metal foam.

2. The method according to claim 1, wherein the metallic powder comprises any of copper, nickel, tungsten, iron, platinum, cobalt, or any combinations thereof.

3. The method according to claim 1, wherein the metallic powder comprises any metallic alloy.

4. The method according to claim 1, wherein the sacrificial particles comprise any of potassium carbonate, magnesium oxide, sodium carbonate, a carbonate, a nitrate salt, any salts oxide, or any combinations thereof.

5. The method according to claim 1, wherein the sacrificial particles comprise any of a polymer or plastic ball in micro or nanoscale or any combination thereof.

6. The method according to claim 1, further comprising annealing the porous metal foam at an annealing temperature.

7. The method according to claim 1, further comprising removing remaining sacrificial particles using a chemical solution.

8. The method according to claim 1, further comprising magnetizing the porous metal foam by applying an electric current.

9. The method according to claim 7, further comprising:

filling voids of the porous metal foam with a polymer; and

implanting magnetic nanoparticles into the polymer.

11. The method according to claim 9, further comprising fusing the sacrificial particulates using any of heat or a chemical solvent.

12. The method according to claim 9, wherein a porosity of the metal foam is selected by varying the pressure, size, or spacing of the sacrificial particulates.

13. The method according to claim 9, wherein when the sacrificial particulates comprise a polymer the metal is deposited as a coating on outer surfaces of the sacrificial particulates.

14. The method according to claim 9, wherein when the sacrificial particulates comprise a salt, the metal is deposited in such a way that the voids of the matrix are filled and the sacrificial particulates are removed.

15. The method according to claim 9, further comprising applying any of a vacuum and pressure within the cavity to enhance the depositing of the metal.

16. The method according to claim 9, further comprising:

depositing a plurality of layers of the metal onto outer surfaces of the sacrificial particulates;

forming a highly order pyrolytic graphite of the plurality of layers; and

heat treating the highly order pyrolytic graphite to form a diamond-liked carbon coating.

17. The method according to claim 9, wherein the mold comprises at least one of metal, alloy, ceramic, or plastic having any geometric configuration, further wherein the mold and metal foam are configured for use as a battery or a heat transfer element.

19. The method according to claim 17, the graphene nanofoam can be constructed with any two dimensional material.

20. The method according to claim 17, further comprising filling voids of the graphene nanofoam to enhance electrical and thermal and mechanical properties of the graphene nanofoam.

21. The method according to claim 17, further comprising any of:

storing hydrogen gas in the graphene nanofoam;

or

filling voids of the graphene nanofoam with an electrolyte to create a battery.

10. A method, comprising:

providing a mold having a cavity;

placing or direct three-dimensional printing of sacrificial particulates in the cavity of the mold in such a way that a matrix is formed having voids;

applying pressure to the sacrificial particulates while the sacrificial particulates are inside the cavity;

depositing a metal onto the sacrificial particulates using any of chemical vapor deposition, physical vapor deposition, or electroless or electrolytic plating; and

vaporizing the sacrificial particulates or diluting the sacrificial particulates with a chemical solvent to reveal a metal foam.

18. A method for producing a graphene nanofoam, comprising:

providing a metal foam having a matrix with voids;

depositing a layer of graphene on outer surfaces of the metal foam; and

removing the metal foam such that a graphene nanofoam remains.