Novel polymer-metal based method for open cell metal foams production

Abstract

Metal foams have acquired popular interest in recent years and are potentially useful for many applications due to their light weight, high specific stiffness, high surface to volume ratio, and adjustable cell structure. Here, current methods of producing metal foams are briefly reviewed. The requirements for high porosity metal foams with open cells are discussed. A novel powder metallurgy route involving a polymeric vehicle is introduced that can readily generate open cell foams with porosity greater than 90%. Coarse Ti powder and fine carbonyl iron powder were tested. Although the resulting polymer metal foam was closed cell, particles were not retained in the windows. Upon pyrolysis to remove the resin, the windows opened and the final sintered metal foam was highly reticulated. Such foams offer a fine reticulated structure with cell diameters in the region of 100-200 μm, and may find applications in the areas of catalysis, biomaterials, and composites. © 2000 IoM Communications Ltd.