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Synthesis of open-cell metal foams by templated directed vapor deposition

Published online by Cambridge University Press:  31 January 2011

Douglas T. Queheillalt ,
Derek D. Hass ,
David J. Sypeck  and
Haydn N. G. Wadley
Douglas T. Queheillalt
Affiliation:
Department of Materials Science and Engineering, School of Engineering and Applied Science, University of Virginia, Charlottesville, Virginia 22904
Derek D. Hass
Affiliation:
Department of Materials Science and Engineering, School of Engineering and Applied Science, University of Virginia, Charlottesville, Virginia 22904
David J. Sypeck
Affiliation:
Department of Materials Science and Engineering, School of Engineering and Applied Science, University of Virginia, Charlottesville, Virginia 22904
Haydn N. G. Wadley
Affiliation:
Department of Materials Science and Engineering, School of Engineering and Applied Science, University of Virginia, Charlottesville, Virginia 22904
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Abstract

Low-density, open-cell nickel base superalloy foams have been synthesized by a high-rate, electron beam-directed vapor deposition process and their mechanical properties evaluated. The deposition process uses an open-cell polymer foam template upon which is deposited a metal alloy coating. The electron beam evaporated flux was entrained in a rarefied transonic gas jet and propagated along the flow stream lines through the polymer structure. After vapor deposition, the polymer template was removed by low-temperature thermal decomposition. The resultant ultralightweight metal foams consisted of a three-dimensional open cell, reticulated structure possessing hollow triangular ligaments with relative densities of <3%. Their mechanical integrity was increased by either pressureless or transient liquid phase sintering. The mechanical properties of these ultralightweight metal foams were comparable to theoretical predictions for open-cell, reticulated foams.

Type
Articles
Information
Journal of Materials Research , Volume 16 , Issue 4 , April 2001 , pp. 1028 - 1036
Copyright
Copyright © Materials Research Society 2001

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