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Powder-based material system with stable porosity

  • US 9,186,866 B2
  • Filed: 01/10/2012
  • Issued: 11/17/2015
  • Est. Priority Date: 01/10/2012
  • Status: Active Grant
First Claim
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1. A method of fabricating a powder-based material system having stable porosity, comprising:

  • selecting a metal material and a ceramic material with respective coefficients of thermal expansion that are within 15% of each other throughout an operating temperature range plus a co-sintering temperature range;

    forming a substrate from a powder of the metal material;

    arranging a layer on the substrate, wherein the layer comprises a powder of the ceramic material containing at least 1% by volume of ceramic nano-particles having an average diameter of less than 100 nm and a plurality of hollow ceramic shapes; and

    co-sintering the substrate and the layer under mechanical pressure within the co-sintering temperature range effective to form a bond there between and to achieve a final density of the substrate and a final density of the layer providing a material system with a stable degree of porosity during subsequent operation in the operating temperature range.

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