Method to Produce High Porosity Metal Foam using Gelation of Water Base Binder

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  • Shimizu Toru
    National Institute of Advanced Industrial Science and Technology
  • Matsuzaki Kunio
    National Institute of Advanced Industrial Science and Technology
  • Kikuchi Kaoru
    National Institute of Advanced Industrial Science and Technology
  • Kanetake Naoyuki
    Department of Material Science and Engineering, Graduate School of Engineering, Nagoya University

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Other Title
  • 水溶性高分子バインダーのゲル化反応を利用した高気孔率発泡金属の作製手法
  • スイヨウセイ コウブンシ バインダー ノ ゲルカ ハンノウ オ リヨウ シタ コウキコウリツ ハッポウ キンゾク ノ サクセイ シュホウ

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Several methods have been developed for producing high-porosity open-cell metal foams, but no method is available for producing closed-cell type metal foams with a porosity of more than 95 %. We therefore developed a novel process for producing a high-porosity closed-cell metal foam using a hydro-gel binder. This process is gelled a slurry which contains a metal powder, an aqueous polymer solution and a foaming agent. When the gelled slurry is heated, the foaming agent causes it to foam; this develops the proper conditions for generating a closed-cell structure. We applied this method to making stainless steel foams and obtained metal foams with porosities of more than 98 %. This method is not only used for to producing metal foams, but could be applied in producing ceramics foams.

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