Porous Metals with Directional Pores

291 Pages·2013·13.044 MB·English

by  Hideo Nakajima (auth.)

Hideo Nakajima
Porous
Metals with
Directional
Pores
Porous Metals with Directional Pores

Hideo Nakajima
Porous Metals
with Directional Pores
HideoNakajima
Director,TheWakasaWanEnergyResearchCenter
Tsuruga,Japan
EmeritusProfessor,OsakaUniversity
Suita,Japan
ISBN978-4-431-54016-8 ISBN978-4-431-54017-5(eBook)
DOI10.1007/978-4-431-54017-5
SpringerTokyoHeidelbergNewYorkDordrechtLondon
LibraryofCongressControlNumber:2013942871
©SpringerJapan2013
Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart
of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,
recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionor
informationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar
methodologynowknownorhereafterdeveloped.Exemptedfromthislegalreservationarebriefexcerpts
inconnectionwithreviewsorscholarlyanalysisormaterialsuppliedspecificallyforthepurposeofbeing
enteredandexecutedonacomputersystem,forexclusiveusebythepurchaserofthework.Duplication
ofthispublicationorpartsthereofispermittedonlyundertheprovisionsoftheCopyrightLawofthe
Publisher’s location, in its current version, and permission for use must always be obtained from
Springer.PermissionsforusemaybeobtainedthroughRightsLinkattheCopyrightClearanceCenter.
ViolationsareliabletoprosecutionundertherespectiveCopyrightLaw.
The use of general descriptive names, registered names, trademarks, service marks, etc. in this
publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexempt
fromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse.
While the advice and information in this book are believed to be true and accurate at the date of
publication,neithertheauthorsnortheeditorsnorthepublishercanacceptanylegalresponsibilityfor
anyerrorsoromissionsthatmaybemade.Thepublishermakesnowarranty,expressorimplied,with
respecttothematerialcontainedherein.
Printedonacid-freepaper
SpringerispartofSpringerScience+BusinessMedia(www.springer.com)
Preface
Porousmetallicmaterialssuchasfoamedmetals,sponge-likemetals,structuralcellular
metals,metalswithdirectionalpores,andsinteredmetalsareincreasinglylookedupon
aspotentiallight-weightstructuralandfunctionalmaterialswith,forexample,superior
sound absorption, damping, and filtering properties. The porous metals are a new
categoryofpromisingengineeringmaterialsfromthepointofviewofbothfundamen-
talscienceandindustrialapplications.Torealizesuchapplications,variousproblems
in fabrication such as uniformity in pore size and porosity controlled with variable
factorsmustbesolved;furthermore,theirpropertiesmustbesufficientlyunderstood
and elucidated. Toward that end, investigations into the science and technology of
porousandfoamedmetallicmaterialsdefinitelyhavebeenexpandedrecently.
Itiswellunderstoodthatporousandfoamedmetalsshouldbeusefulinsolvingsome
major issues of the twenty-first century such as environmental preservation, aging
societies, and energy problems. For example, foamed aluminum is expected to be
usedforcrashabsorbersinautomobilesandforsoundabsorption,whileporousmetals
withelongateddirectionalporesmaybeusefulformedicaldevices,machinetools,heat
sinks,andinotherways.Therearevariousfabricationmethods,classifiedbypower
sintering, foaming, and casting techniques. Porous metals are further grouped into
porous and cellular metals depending upon the magnitude of their porosity.
Amongtheseporousandfoamedmetals,theporousmetalswithdirectionalpores,
theso-calledlotusandgasarmetals,havebeenattractingattentionowingtotheirlong
cylindricalporesalignedinonedirection.Theseareconsiderednewtypesofporous
metals.Recently,methodsfortheirfabricationhavealmostbeenestablishedatthe
mass production level. Various unique physical, chemical, and mechanical
properties have been discovered and already have been fairly well understood. In
addition,severalapplicationsareproceedingattheindustrialmanufacturinglevel.
Thus,Iconsiderthatthepresentisagoodtimetoorganizeandpresentthescienceand
relevanttechnologyofporousmetalswithdirectionalpores.Ihopethatreadersof
thisbookcanunderstandthepresentstatusofresearchanddevelopmentofporous
metalswithdirectionalporesforthebenefitofprogressintheirresearch.
Tsuruga,Japan HideoNakajima
Suita,Japan
v

Acknowledgements
The author would like to acknowledge the collaborations with Prof. S.K. Hyun
of Inha University in Korea, Prof. T. Ikeda of Ibaraki University, Prof. S. Suzuki
of Waseda University, Dr. M. Tane, Dr. T. Ide, Prof. K. Nakata, Prof. M. Hirao,
Prof. H. Utsunomiya, Prof. T. Nakano, Prof. S. Fujimoto of Osaka University,
Prof. O. Yoshinari of Nagoya Institute of Technology, Dr. S. Ueno of Nippon
University,Dr.T.MurakamiofTohokuUniversity,Prof.B.-Y.HurofGyeongsang
National University in Korea, Dr. V. Shapovalov of MER Corporation, Ltd. of
USA, Dr. Y. Higuchi of Osaka Dental University, Prof. T. Ogushi of Hiroshima
InternationalUniversityandDr.H.ChibaofMitsubishiElectricCorporation,Ltd.
The author also expresses his appreciation to Prof. G. Stephani of Fraunhofer
Institute and Prof. J. Banhart of Helmholtz Center Berlin of Germany, and
Prof.D.DunandofNorthwesternUniversityofUSA.
vii

Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 PorousMaterialsWidespreadinNaturalWorld. . . . . . . . . . . . . 1
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 VariousFabricationMethodsofCellular
MetalsandFoamedMetals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 MaterialsDefinition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 VariousFabricationMethods. . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 MeltGasInjection(AirBubbling). . . . . . . . . . . . . . . . . 8
2.2.2 Gas-ReleasingParticleDecomposition
intheMelt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.3 Gas-ReleasingParticleDecomposition
inSemisolids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 9
2.2.4 CastingUsingaPolymerorWaxPrecursor
asTemplate. . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . 10
2.2.5 MetalDepositiononCellularPreforms. . . . . . . . . . . . . . 10
2.2.6 EntrappedGasExpansion. . . . . . . . . . . . . . . . . . . . . . . 11
2.2.7 HollowSphereStructures. . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.8 Co-compactionorCastingofTwoMaterials,
OneLeachable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 FabricationMethodsofPorousMetals
withDirectionalPores. . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. 13
3.1 HistoricalBackground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.1 IceWormholes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.2 PorousMetalswithDirectionalPores. . . . . . . . . . . . . . . 16
3.2 High-PressureGasMethod(PGM). . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 MoldCastingTechnique. . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.2 ContinuousZoneMeltingTechnique. . . . . . . . . . . . . . . 20
3.2.3 ContinuousCastingTechnique. . . . . . . . . . . . . . . . . . . . 24
ix