CN109202046B - Layered periodic pore structure aluminum or aluminum alloy foam and preparation method thereof - Google Patents

Layered periodic pore structure aluminum or aluminum alloy foam and preparation method thereof Download PDF

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CN109202046B
CN109202046B CN201811066476.XA CN201811066476A CN109202046B CN 109202046 B CN109202046 B CN 109202046B CN 201811066476 A CN201811066476 A CN 201811066476A CN 109202046 B CN109202046 B CN 109202046B
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aluminum
foam
pore structure
polyurethane foam
gypsum
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CN109202046A (en
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张磊
左孝青
周芸
罗晓旭
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Kunming University of Science and Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/04—Casting by dipping
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores

Abstract

The invention discloses aluminum or aluminum alloy foam with a layered periodic pore structure and a preparation method thereof, belonging to the field of porous metal materials. Soaking polyurethane foam in water-soluble polyurethane emulsion to regulate and control the aperture and porosity of the polyurethane foam; alternately matching the impregnated large-aperture layer polyurethane foam and small-aperture layer polyurethane foam to obtain layered periodic pore structure polyurethane foam; then the gypsum slurry is infiltrated into the layered periodic pore structure polyurethane foam, and a precursor is prepared by drying and roasting; and finally, preheating, percolating and dissolving gypsum to remove the gypsum from the precursor to obtain the layered periodic pore structure aluminum or aluminum alloy foam. The invention overcomes the problems of difficult seepage precursor preparation and pore structure control and overhigh porosity of the commercially available polyurethane foam in the preparation of the layered periodic aluminum or aluminum alloy foam by a seepage casting method, and the obtained aluminum or aluminum alloy foam has controllable layered periodic pore structure, can realize diversified layered periodic pore structure collocation, has simple preparation process and can realize industrial production.

Description

Layered periodic pore structure aluminum or aluminum alloy foam and preparation method thereof
Technical Field
The invention relates to aluminum or aluminum alloy foam with a layered periodic pore structure and a preparation method thereof, belonging to the field of porous metal materials.
Background
The aluminum or aluminum alloy foam is a structure-function integrated porous metal material, and has the characteristics of light weight, high specific strength, damping, sound absorption and vibration reduction, fire resistance, flame retardance, energy absorption and the like. The foamed aluminum with the through hole structure has wide application prospect in the fields of sound absorption and noise reduction of environments such as audio rooms, engine (electric) rooms, urban viaducts, high-speed rails, airports and the like.
At present, seepage casting is a main method for preparing sound-absorbing aluminum or aluminum alloy foam with a through hole structure, but the conventional seepage method can only obtain the aluminum or aluminum alloy foam with the porosity of about 65%, and the seepage aluminum or aluminum alloy foam with low porosity has the problem of low sound-absorbing coefficient. In order to improve the sound absorption performance of the seepage foamed aluminum, a method for improving the porosity and periodically modulating the pore structure is adopted, and the porosity with better sound absorption performance is usually 79-85%.
In the preparation aspect of seepage high-porosity aluminum or aluminum alloy foam, the high-porosity aluminum or aluminum alloy foam can be prepared by utilizing polyurethane foam in an investment casting method, but the porosity is too high, generally 88-93%, and the sound absorption performance is reduced. In the aspect of preparing high-porosity layered periodic pore structure aluminum or aluminum alloy foam, the problems of complex preparation process of a seepage precursor, uneven layered structure and difficult control of the pore structure exist.
Disclosure of Invention
The invention aims to provide a layered periodic pore structure aluminum or aluminum alloy foam, wherein the aluminum or aluminum alloy foam is tabular in appearance and is a layered periodic pore structure material, and is matched in a manner that large-pore-diameter aluminum or aluminum alloy foam and small-pore-diameter aluminum or aluminum alloy foam are mutually alternated, namely, the aluminum or aluminum alloy foam is matched in a manner of AB, ABAB and ABABAB. Wherein the aperture of the single layer is 0.3-0.9 mm, the porosity of the single layer is 79-85%, the thickness of the single layer is 2.5-5 mm, the number of layers is 2-6, and the total thickness is 5-30 mm.
The invention also aims to provide a preparation method of the layered periodic pore structure aluminum or aluminum alloy foam, which solves the problems of difficulty in seepage precursor preparation and pore structure control and overhigh porosity of commercially available polyurethane foam in the preparation of the layered periodic aluminum or aluminum alloy foam by a seepage casting method, and the obtained aluminum or aluminum alloy foam has a controllable layered periodic pore structure, can realize diversified layered periodic pore structure collocation, has a simple preparation process and can realize industrial production; the method specifically comprises the following steps:
(1) and (3) regulating and controlling the pore structure of polyurethane foam: soaking polyurethane foam with the aperture of 0.9-1.2 mm and the porosity of 88-91% in water-soluble polyurethane emulsion for 10-25 min, drying the soaked polyurethane foam, and repeating the soaking process for 2-4 times to regulate and control the aperture and the porosity of the polyurethane foam to obtain the polyurethane foam with the aperture of 0.3-0.9 mm and the porosity of 79-85%;
(2) the polyurethane foam is matched in a layered manner: matching the polyurethane foams with the same thickness obtained in the step (1) according to a mode that the large-aperture polyurethane foams and the small-aperture polyurethane foams are mutually alternated, namely, matching in a mode of AB, ABAB and ABABAB. 0.6-0.9 mm, porosity: 81.8-85%, thickness: 2.5-5 mm; b is small-aperture layer polyurethane foam, the aperture is: 0.3-0.6 mm, porosity: 79-81.8%, thickness: 2.5-5 mm, wherein the aperture difference between A and B is 0.3-0.5 mm, and the layered periodic pore structure polyurethane foam obtained by matching is placed into a casting mold;
(3) preparing an inverse laminar periodic pore structure seepage precursor: pouring the gypsum slurry into a casting mold and filling the pores of the polyurethane foam with the gypsum slurry, curing the gypsum slurry to obtain gypsum/polyurethane foam with a layered periodic structure, drying and calcining the gypsum/polyurethane foam to remove the polyurethane foam in the gypsum/polyurethane foam, and obtaining a gypsum seepage precursor with an inverted layered periodic pore structure opposite to the target layered periodic pore structure;
(4) seepage and water-soluble gypsum removing paste
Figure DEST_PATH_IMAGE001
Seepage flow: putting the gypsum seepage precursor with the reverse-layer periodic pore structure prepared in the step (3) into a seepage mold for preheating, and then infiltrating an aluminum or aluminum alloy melt into the pores of the gypsum seepage precursor with the reverse-layer periodic pore structure by utilizing positive pressure or negative pressure to obtain a mixture of aluminum or aluminum alloy and gypsum;
Figure 48393DEST_PATH_IMAGE002
dissolving in water to remove gypsum: and (3) removing gypsum in the mixture by water dissolution to obtain the flat-plate-shaped aluminum or aluminum alloy foam with the layered periodic pore structure.
Preferably, the drying conditions in step (1) of the present invention are: drying at 50-80 ℃ for 25-40 min.
Preferably, the drying conditions in step (3) of the present invention are: drying for 4-5.5 h at 50-80 ℃, wherein the calcining conditions are as follows: roasting at 650-710 ℃ for 5-6.5 h.
Preferably, the formula of the gypsum slurry in the step (3) of the invention is as follows: gypsum powder: 37.5 to 45 weight percent of MgSO4: 2-5 wt%, bauxite: 3-7.5 wt%, and the balance being deionized water.
Preferably, the preheating process in step (4) of the present invention is: and heating the seepage mold filled with the seepage precursor to 540-570 ℃ and preserving the heat for 20-50 min.
Preferably, the melting and heat preservation process of the aluminum or aluminum alloy melt in the step (4) of the invention comprises the following steps: heating the mixture to a temperature 20-80 ℃ higher than the melting point or the liquidus temperature, and then melting and preserving heat for 30-60 min.
The water-soluble polyurethane emulsion is a commercially available water-soluble polyurethane emulsion, and the mass percentage of polyurethane is 35%.
The aluminum is industrial pure aluminum, and the aluminum alloy is binary or multi-element aluminum alloy formed by aluminum and elements such as Si, Mg, Cu and the like.
The invention principle is as follows:
1. regulation and control principle of polyurethane foam pore structure
The investment casting method can prepare high-porosity aluminum or aluminum alloy foam by utilizing polyurethane foam, but the porosity is too high, and the sound absorption performance is reduced. Researches show that the aperture of the aluminum or aluminum alloy foam is 0.3-0.9 mm, the porosity is 79-85%, and the sound absorption performance is the best. The method comprises the steps of soaking commercially available polyurethane foam with the aperture of 0.9-1.2 mm and the porosity of 88-91% in water-soluble polyurethane emulsion, drying the water-soluble polyurethane emulsion to form a polyurethane film, and curing the polyurethane film on the surface of the polyurethane foam, so that the thickness of the hole wall of the polyurethane foam is increased, and the purposes of reducing the porosity and reducing the pore structure of the polyurethane foam are achieved.
The relationship between pore size and the number of impregnations is:
Figure 271564DEST_PATH_IMAGE004
(1)
(1) in the formula, d: target polyurethane foam pore size (mm, d is more than or equal to 0.3mm and less than or equal to 0.9 mm)
d0: pore size (mm, d is more than or equal to 0.9mm and less than or equal to 1.2 mm) of commercially available polyurethane foam
X: number of dips (X is 2. ltoreq. X.ltoreq.4)
The relationship between porosity and the number of impregnations is:
Figure 602051DEST_PATH_IMAGE006
（2）
(2) in the formula (I), the compound is shown in the specification,
Figure 391016DEST_PATH_IMAGE008
: target polyurethane foam porosity (%, 79% or less)
Figure DEST_PATH_IMAGE010
≤85%）
Figure DEST_PATH_IMAGE012
: the porosity of the commercial polyurethane foam (percent, 88 percent or less)
Figure DEST_PATH_IMAGE014
≤91%）
X: number of dips (X is 2. ltoreq. X.ltoreq.4)
2. Selection and collocation principle of layered periodic pore structure
The aluminum or aluminum alloy foam with the single pore structure has the problems of narrow absorption peak frequency range, low sound absorption coefficient and low sound absorption valley, and the periodic modulation of the pore structure of the aluminum or aluminum alloy foam can improve the whole sound absorption performance of the aluminum or aluminum alloy foam.
(1) Selection principle of aperture, porosity and thickness of single-layer aluminum or aluminum alloy foam
Pore diameter (d): the smaller the pore size of the aluminum or aluminum alloy foam is, the larger the specific surface area is, and the better the sound absorption performance is; but the aluminum or aluminum alloy foam with the aperture smaller than 0.3mm has large difficulty in the preparation process. Therefore, the reasonable range of the pore diameter of the layered periodic pore structure is 0.3-0.9 mm.
Porosity (θ): the sound absorption performance of the aluminum or aluminum alloy foam is increased and then reduced along with the increase of the porosity, so that the porosity range is 79-85%.
Single layer thickness (H)0): the sound absorption performance of the aluminum or aluminum alloy foam is increased along with the increase of the thickness of the single layer, but the difficulty and the cost of the preparation process are increased due to the overlarge thickness, and the reasonable thickness of the single layer of the aluminum or aluminum alloy foam is 2.5-5 mm.
(2) Interlayer aperture difference collocation principle of layered periodic pore structure
Periodically matching the aluminum or aluminum alloy foam according to the pore size to form a (A + B) × n type periodic pore structure, wherein A = large pore layer (d)A：0.6~0.9mm，θA：81.8~85%，HA: 2.5 to 5 mm), B = small pore size layer (d)B：0.3~0.6mm，θB：79~81.8%，HB: 2.5-5 mm), n = number of cycles (1-3).
The thickness of the single layer of the (A + B) × n layered periodic pore structure is the same, the pore size shows periodic change, the pore structures A and B are periodically matched according to the pore size difference of 0.3-0.5 mm, and the aluminum or aluminum alloy foam can obtain the best sound absorption effect.
(3) Selection principle of layer number and total thickness of layered periodic pore structure
The greater the number of layers (N) of the aluminum or aluminum alloy foam, the total thickness (H)General assembly) The larger the size, the greater the flow resistance and energy loss during sound wave propagation, and the better the sound absorption performance. However, too many layers and total thickness will increase the difficulty of the preparation process, consume too much sound absorption space and increase the cost. The reasonable total number of layers N = 2-6 of the periodic pore structure aluminum or aluminum alloy foam, the number N = 1-3 of the periods, and the total thickness HGeneral assembly=5~30mm。
The invention has the beneficial effects that: the method of the invention overcomes the problems of difficult seepage precursor preparation and pore structure control and overhigh porosity of the polyurethane foam sold in the market in the preparation of the layered periodic aluminum or aluminum alloy foam by a seepage casting method; the obtained aluminum or aluminum alloy foam has controllable layered periodic pore structure, can realize diversified layered periodic pore structure collocation, has simple preparation process and can realize industrial production. The layered periodic pore structure aluminum or aluminum alloy foam prepared by the method has good sound absorption performance.
Drawings
FIG. 1 is a flow chart of the preparation process of the present invention.
FIG. 2 is a schematic representation of a layered periodic cell structure aluminum or aluminum alloy foam of example 1;
FIG. 3 is a schematic representation of the layered periodic cell structure aluminum or aluminum alloy foam of examples 2 and 3;
FIG. 4 is a schematic representation of a layered periodic cell structure aluminum or aluminum alloy foam described in example 4.
Detailed Description
The invention will be described in more detail with reference to the following figures and examples, but the scope of the invention is not limited thereto.
Example 1
The preparation method of the Al-Si12 alloy foam with the two-layer 1-period pore structure, which is described in the embodiment, comprises the following specific steps:
(1) and (3) regulating and controlling the pore structure of polyurethane foam: commercially available polyurethane foam with the aperture of 1.2mm, the porosity of 91 percent, the aperture of 1.0mm and the porosity of 89 percent is placed in water-soluble polyurethane emulsion with the mass percentage of 35 percent for soaking for 10min, then the polyurethane foam is taken out and dried in a drying oven at 80 ℃ for 25min, and the soaking process is repeated for 2 and 4 times respectively to regulate and control the aperture and the porosity of the polyurethane foam, so that the polyurethane foam with the aperture of 0.9mm, the porosity of 85 percent, the aperture of 0.4mm and the porosity of 80 percent is obtained.
(2) Layered collocation of polyurethane foam
And (2) matching the polyurethane foam with the same thickness regulated and controlled by the pore structure in the step (1) according to the structure AB, wherein A is large-pore-diameter layer polyurethane foam (the pore diameter is 0.9mm, the porosity is 85 percent, and the thickness is 2.5 mm), B is small-pore-diameter layer polyurethane foam (the pore diameter is 0.4mm, the porosity is 80 percent, and the thickness is 2.5 mm), and the pore diameter difference between A and B is 0.5mm, and placing the layered periodic pore structure polyurethane foam obtained by matching into a casting mold.
(3) Preparing an inverse laminar periodic pore structure seepage precursor: proportioning gypsum powder: 37.5 wt%, MgSO 4: 5wt%, bauxite: and 7.5 wt% of gypsum slurry is poured into a casting mould and is filled with pores of polyurethane foam, the gypsum slurry is taken out of the casting mould after being solidified, dried at 50 ℃ for 5.5h and then roasted at 650 ℃ for 6.5h to remove the polyurethane foam, and a gypsum seepage precursor with an inverse lamellar periodic pore structure opposite to the target lamellar periodic pore structure is obtained.
(4) Seepage and water-soluble gypsum removing paste
Figure 529234DEST_PATH_IMAGE001
Seepage flow: putting the gypsum seepage precursor with the reverse-layered periodic pore structure prepared in the step (3) into a seepage mold, and heating the seepage mold and the gypsum seepage precursorKeeping the temperature at 540 ℃ for 50min for preheating; heating the Al-Si12 alloy to 660 ℃ to melt and preserving heat for 30min to obtain Al-Si12 alloy melt; and infiltrating the aluminum alloy melt into gypsum seepage precursor pores with the reverse layered periodic pore structure by utilizing positive pressure to obtain a mixture of the aluminum alloy and the gypsum.
Figure 239701DEST_PATH_IMAGE002
Dissolving in water to remove gypsum: the gypsum in the mixture was removed by water dissolution to give two layers of 1 period (AB) pore structure Al-Si12 alloy foam (shown in FIG. 2), wherein layer A had parameters of pore diameter 0.9mm, porosity 85% and thickness 2.5mm, layer B had parameters of pore diameter 0.4mm, porosity 80% and thickness 2.5mm, and the alloy foam had a total thickness of 5mm and a plate-like appearance.
Example 2
The preparation method of the four-layer 2-period-hole-structure ZL101 alloy foam comprises the following specific steps:
(1) and (3) regulating and controlling the pore structure of polyurethane foam: commercially available polyurethane foam with the aperture of 1.1mm, the porosity of 90 percent, the aperture of 0.93mm and the porosity of 88.5 percent is placed in water-soluble polyurethane emulsion with the mass percentage of 35 percent for soaking for 15min, then the polyurethane foam is taken out and dried in a drying oven for 30min at 70 ℃, the soaking process is repeated for 2 and 3 times respectively to regulate and control the aperture and the porosity of the polyurethane foam, and the polyurethane foam with the aperture of 0.8mm, the porosity of 84 percent, the aperture of 0.5mm and the porosity of 80.8 percent is obtained.
(2) Layered collocation of polyurethane foam
And (2) matching the polyurethane foam with the same thickness regulated and controlled by the pore structure in the step (1) according to the ABAB structure, wherein A is large-pore-diameter layer polyurethane foam (the pore diameter is 0.8mm, the porosity is 84% and the thickness is 3 mm), B is small-pore-diameter layer polyurethane foam (the pore diameter is 0.5mm, the porosity is 80.8% and the thickness is 3 mm), and the pore diameter difference between A and B is 0.3mm, and placing the matched layered periodic pore structure polyurethane foam into a casting mold.
(3) Preparing an inverse laminar periodic pore structure seepage precursor: proportioning gypsum powder: 40 wt%, MgSO 4: 4 wt%, bauxite: pouring 6 wt% of gypsum slurry into a casting mould and filling the gypsum slurry into pores of polyurethane foam, taking out the gypsum slurry from the casting mould after solidification, drying at 60 ℃ for 5h, and roasting at 670 ℃ for 6h to remove the polyurethane foam, thereby obtaining the reverse lamellar periodic pore structure gypsum seepage precursor opposite to the target lamellar periodic pore structure.
(4) Seepage and water-soluble gypsum removing paste
Figure 593453DEST_PATH_IMAGE001
Seepage flow: putting the gypsum seepage precursor with the reverse-layer periodic pore structure prepared in the step (3) into a seepage mold, heating the seepage mold together to 550 ℃, and preserving heat for 40min for preheating; heating the ZL101 alloy to 673 ℃ for melting and preserving heat for 40min to obtain a ZL101 alloy melt; and infiltrating the aluminum alloy melt into gypsum seepage precursor pores with the reverse layered periodic pore structure by utilizing negative pressure to obtain a mixture of the aluminum alloy and the gypsum.
Figure 705766DEST_PATH_IMAGE002
Dissolving in water to remove gypsum: the gypsum in the mixture was removed by water dissolution to obtain a four-layer 2-period (ABAB) pore structure ZL101 alloy foam (shown in figure 3), wherein the parameters of the A layer are 0.8mm pore diameter, 84% porosity and 3mm thickness, the parameters of the B layer are 0.5mm pore diameter, 80.8% porosity and 3mm thickness, the total thickness of the alloy foam is 12mm, and the appearance of the alloy foam is flat.
Example 3
The preparation method of the ZL201 alloy foam with the four-layer 2-period pore structure, which is described in the embodiment, comprises the following specific steps:
(1) and (3) regulating and controlling the pore structure of polyurethane foam: commercially available polyurethane foam with the aperture of 1.0mm, the porosity of 89 percent, the aperture of 0.9mm and the porosity of 88 percent is placed in 35 percent of water-soluble polyurethane emulsion by mass percent for soaking for 20min, then the polyurethane foam is taken out and dried in a drying oven at 60 ℃ for 35min, and the soaking process is repeated for 2 and 4 times respectively to regulate and control the aperture and the porosity of the polyurethane foam, so that the polyurethane foam with the aperture of 0.7mm, the porosity of 83 percent, the aperture of 0.3mm and the porosity of 79 percent is obtained.
(2) Layered collocation of polyurethane foam
And (2) matching the polyurethane foam with the same thickness regulated and controlled by the pore structure in the step (1) according to an ABAB structure, wherein A is large-pore-diameter layer polyurethane foam (the pore diameter is 0.7mm, the porosity is 83 percent, and the thickness is 4 mm), B is small-pore-diameter layer polyurethane foam (the pore diameter is 0.3mm, the porosity is 79 percent, and the thickness is 4 mm), and the pore diameter difference between A and B is 0.4mm, and placing the layered periodic pore structure polyurethane foam obtained by matching into a casting mold.
(3) Preparing an inverse laminar periodic pore structure seepage precursor: proportioning gypsum powder: 42.5wt%, MgSO 4: 3 wt%, bauxite: pouring 4.5wt% of gypsum slurry into a casting mould and filling the gypsum slurry into pores of polyurethane foam, taking the gypsum slurry out of the casting mould after solidification, drying at 70 ℃ for 4.5h, and roasting at 690 ℃ for 5.5h to remove the polyurethane foam, thereby obtaining the gypsum seepage precursor with the reverse lamellar periodic pore structure opposite to the target lamellar periodic pore structure.
(4) Seepage and water-soluble gypsum removing paste
Figure 634408DEST_PATH_IMAGE001
Seepage flow: putting the gypsum seepage precursor with the reverse-layer periodic pore structure prepared in the step (3) into a seepage mold, heating the seepage mold together to 560 ℃, and preserving heat for 30min for preheating; heating the ZL201 alloy to 690 ℃ for melting and preserving heat for 50min to obtain a ZL201 alloy melt; and infiltrating the aluminum alloy melt into gypsum seepage precursor pores with the reverse layered periodic pore structure by utilizing positive pressure to obtain a mixture of the aluminum alloy and the gypsum.
Figure 628908DEST_PATH_IMAGE002
Dissolving in water to remove gypsum: the gypsum in the mixture was removed by water dissolution to obtain a four-layer 2-period (ABAB) pore structure ZL201 alloy foam (shown in figure 3), wherein the parameters of the A layer are 0.7mm pore diameter, 83% porosity and 4mm thickness, the parameters of the B layer are 0.3mm pore diameter, 79% porosity and 4mm thickness, the total thickness of the alloy foam is 16mm, and the appearance of the alloy foam is flat.
Example 4
The preparation method of the industrial pure aluminum foam with the six-layer 3-period pore structure comprises the following specific steps:
(1) and (3) regulating and controlling the pore structure of polyurethane foam: commercially available polyurethane foam with the pore diameter of 1.03mm, the porosity of 89.5 percent, the pore diameter of 0.9mm and the porosity of 88 percent is placed in water-soluble polyurethane emulsion with the mass percentage of 35 percent for soaking for 25min, then the polyurethane foam is taken out and dried for 40min in a drying oven at 50 ℃, the soaking process is repeated for 3 and 4 times respectively to regulate and control the pore diameter and the porosity of the polyurethane foam, and the polyurethane foam with the pore diameter of 0.6mm, the porosity of 81.8 percent, the pore diameter of 0.3mm and the porosity of 79 percent is obtained.
(2) Layered collocation of polyurethane foam
And (2) matching the polyurethane foam with the same thickness regulated and controlled by the pore structure in the step (1) according to the ABABAB structure, wherein A is large-pore-diameter layer polyurethane foam (the pore diameter is 0.6mm, the porosity is 81.8 percent, and the thickness is 5 mm), B is small-pore-diameter layer polyurethane foam (the pore diameter is 0.3mm, the porosity is 79 percent, and the thickness is 5 mm), and the pore diameter difference between A and B is 0.3mm, and placing the matched layered periodic pore structure polyurethane foam into a casting mold.
(3) Preparing an inverse laminar periodic pore structure seepage precursor: proportioning gypsum powder: 45wt%, MgSO 4: 2 wt%, bauxite: pouring 3 wt% of gypsum slurry into a casting mould and filling the gypsum slurry into pores of polyurethane foam, taking out the gypsum slurry from the casting mould after solidification, drying at 80 ℃ for 4h, and roasting at 710 ℃ for 5h to remove the polyurethane foam, thereby obtaining the reverse lamellar periodic pore structure gypsum seepage precursor opposite to the target lamellar periodic pore structure.
(4) Seepage and water-soluble gypsum removing paste
Figure 176564DEST_PATH_IMAGE001
Seepage flow: putting the gypsum seepage precursor with the reverse-layered periodic pore structure prepared in the step (3) into a seepage mold, heating the seepage mold together to 570 ℃, and preserving heat for 20min for preheating; heating industrial pure aluminum to 680 ℃ to melt and preserving heat for 60min to obtain an industrial pure aluminum melt; the industrial pure aluminum melt is infiltrated and reversely by utilizing the negative pressureAnd (3) infiltrating the pores of the precursor with the layered periodic pore structure to obtain a mixture of industrial pure aluminum and gypsum.
Figure 753170DEST_PATH_IMAGE002
Dissolving in water to remove gypsum: the gypsum in the mixture was removed by water dissolution to give six layers of 3-period (ABABAB) pore structured commercial pure aluminum foam (shown in FIG. 4) in which the parameters of layer A were 0.6mm pore size, 81.8% porosity and 5mm thickness, layer B was 0.3mm pore size, 79% porosity and 5mm thickness, and the alloy foam had a total thickness of 30mm and a plate-like appearance.

Claims (6)

1. A preparation method of aluminum or aluminum alloy foam with a layered periodic pore structure is characterized by comprising the following steps:
(1) and (3) regulating and controlling the pore structure of polyurethane foam: soaking polyurethane foam with the aperture of 0.9-1.2 mm and the porosity of 88-91% in water-soluble polyurethane emulsion for 10-25 min, drying the soaked polyurethane foam, and repeating the soaking process for 2-4 times to regulate and control the aperture and the porosity of the polyurethane foam to obtain the polyurethane foam with the aperture of 0.3-0.9 mm and the porosity of 79-85%;
(2) the polyurethane foam is matched in a layered manner: matching the polyurethane foams with the same thickness obtained in the step (1) according to a mode that the large-aperture polyurethane foams and the small-aperture polyurethane foams are mutually alternated, namely, matching in a mode of AB, ABAB and ABABAB. 0.6-0.9 mm, porosity: 81.8-85%, thickness: 2.5-5 mm; b is small-aperture layer polyurethane foam, the aperture is: 0.3-0.6 mm, porosity: 79-81.8%, thickness: 2.5-5 mm, wherein the aperture difference between A and B is 0.3-0.5 mm, and the layered periodic pore structure polyurethane foam obtained by matching is placed into a casting mold;
(3) preparing an inverse laminar periodic pore structure seepage precursor: pouring the gypsum slurry into a casting mold and filling the pores of the polyurethane foam with the gypsum slurry, curing the gypsum slurry to obtain gypsum/polyurethane foam with a layered periodic structure, drying and calcining the gypsum/polyurethane foam to remove the polyurethane foam in the gypsum/polyurethane foam, and obtaining a gypsum seepage precursor with an inverted layered periodic pore structure opposite to the target layered periodic pore structure;
(4) seepage and water-soluble gypsum removing paste
Seepage flow: putting the gypsum seepage precursor with the reverse-layer periodic pore structure prepared in the step (3) into a seepage mold for preheating, and then infiltrating an aluminum or aluminum alloy melt into the pores of the gypsum seepage precursor with the reverse-layer periodic pore structure by utilizing positive pressure or negative pressure to obtain a mixture of aluminum or aluminum alloy and gypsum;
dissolving in water to remove gypsum: dissolving the gypsum in the mixture by water to obtain the tabular layered periodic pore structure aluminum or aluminum alloy foam;
the aluminum or aluminum alloy foam is flat-plate-shaped in appearance, is a layered periodic pore structure material, and is matched in a mode that large-aperture aluminum or aluminum alloy foam and small-aperture aluminum or aluminum alloy foam are mutually alternated, namely, the aluminum or aluminum alloy foam is matched in a mode of AB, ABAB and ABABAB. Wherein the aperture of the single layer is 0.3-0.9 mm, the porosity of the single layer is 79-85%, the thickness of the single layer is 2.5-5 mm, the number of layers is 2-6, and the total thickness is 5-30 mm.
2. The method of producing the layered periodic cell structured aluminum or aluminum alloy foam of claim 1, wherein: the drying conditions in the step (1) are as follows: drying at 50-80 ℃ for 25-40 min.
3. The method of producing the layered periodic cell structured aluminum or aluminum alloy foam of claim 1, wherein: the drying conditions in the step (3) are as follows: drying for 4-5.5 h at 50-80 ℃, wherein the calcining conditions are as follows: roasting at 650-710 ℃ for 5-6.5 h.
4. The method of producing the layered periodic cell structured aluminum or aluminum alloy foam of claim 1, wherein: the formula of the gypsum slurry in the step (3) is as follows: gypsum powder: 37.5 to 45 weight percent of MgSO4: 2-5 wt%, bauxite: 3-7.5 wt%, and the balance being deionized water.
5. The method of producing the layered periodic cell structured aluminum or aluminum alloy foam of claim 1, wherein: the preheating process in the step (4) comprises the following steps: and heating the seepage mold filled with the seepage precursor to 540-570 ℃ and preserving the heat for 20-50 min.
6. The method of producing the layered periodic cell structured aluminum or aluminum alloy foam of claim 1, wherein: the melting and heat preservation process of the aluminum or aluminum alloy melt in the step (4) comprises the following steps: heating the mixture to a temperature 20-80 ℃ higher than the melting point or the liquidus temperature, and then melting and preserving heat for 30-60 min.
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