US20160090653A1 - Method For Producing A Metal Foam And Method For Producing Particles Suitable For Said Method - Google Patents

Method For Producing A Metal Foam And Method For Producing Particles Suitable For Said Method Download PDF

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Publication number
US20160090653A1
US20160090653A1 US14/892,073 US201414892073A US2016090653A1 US 20160090653 A1 US20160090653 A1 US 20160090653A1 US 201414892073 A US201414892073 A US 201414892073A US 2016090653 A1 US2016090653 A1 US 2016090653A1
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United States
Prior art keywords
particles
blowing agent
layer
metal
substrate
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Abandoned
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US14/892,073
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English (en)
Inventor
Jens Dahl Jensen
Ralph Reiche
Daniel Reznik
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Siemens AG
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Siemens AG
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Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JENSEN, JENS DAHL, REICHE, RALPH, REZNIK, DANIEL
Publication of US20160090653A1 publication Critical patent/US20160090653A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1134—Inorganic fillers
    • 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

Definitions

  • the invention relates to a method for producing a metal foam, in which metal-containing particles together with particles containing a solid blowing agent are deposited as a layer on a substrate by cold spraying. Thereafter, the blowing agent is activated, the pores of the metal foam forming in the layer. Activation of this type can be performed, for example, by means of a heat treatment. In this process, the layer is heated to such an extent that the blowing agent changes from the solid state to a gaseous state. The increase in pressure associated therewith leads to the formation of pores in the metallic matrix. The heat treatment is carried out in temperature ranges in which the metallic matrix is softened to such an extent that the pores can form.
  • the invention relates to a method for producing coated particles.
  • brittle materials like the materials of the blowing agent, can be deposited in the metallic matrix formed by the substantially more ductile metallic particles only to the extent to which the deformation of the particles upon impact allows for the more brittle particles to be incorporated. Therefore, the pore density is limited in the deposition of the particles of the blowing agent.
  • One embodiment provides a method for producing a metal foam, comprising depositing metal-containing particles together with particles containing a solid blowing agent as a layer on a substrate by cold spraying, and activating the blowing agent, with the pores of the metal foam forming in the layer, wherein coated particles having a core consisting of the blowing agent and a metallic shell are used as particles which contain the blowing agent.
  • aluminum, copper, nickel, iron, steel or silver are used as materials for the shell.
  • the material of the shell is the same as the material of the exclusively metal-containing particles.
  • the material of the core is a metal hydride, in particular magnesium hydride or titanium hydride, or a carbonate, in particular calcium carbonate or magnesium carbonate.
  • the mixing ratio between the particles containing the blowing agent and exclusively metal-containing particles is varied during the coating process.
  • a gradient layer with a variable density of the pores is produced.
  • the density of the pores in the boundary layer adjacent to the substrate and/or in the boundary layer close to the surface is reduced to zero by processing only the exclusively metal-containing particles there.
  • the density of the pores in the boundary layer adjacent to the substrate is maximized by processing only the particles containing blowing agent.
  • the metal foam is produced by a heat treatment of the layer which follows the conclusion of the coating process.
  • the energy input during the cold spraying and/or an energy input into the substrate are chosen to be so high that the particles containing the blowing agent are heated to a temperature above the reaction temperature of the blowing agent when they impact on the substrate.
  • Another embodiment provides a method for producing coated particles, wherein said particles are produced from cores consisting of a blowing agent by surrounding these cores with shells consisting of a metal.
  • an electroless electrochemical method is used for coating the cores with the shell.
  • FIG. 1 schematically shows an exemplary embodiment of the method according to the invention
  • FIGS. 2 to 9 show various exemplary embodiments of the porous layers, in each case before and after activation of the blowing agent, and
  • FIG. 10 shows an exemplary embodiment of the method for producing the coated particles.
  • Embodiments of the invention provide a method for producing a metal foam by cold spraying and also a method for producing suitable particles for the cold spraying method, which produce metal foams having a pore density and pore type which are variable over the greatest possible spectrum.
  • Some embodiments provide a method in which coated particles having a core consisting of the blowing agent and a metallic shell are used as particles which contain the blowing agent. These can then be deposited together with the metal-containing particles, the metal-containing particles containing in particular exclusively metal.
  • the advantage of coating the blowing agent with a metallic material lies in the fact that these coated particles have a behavior similar to the particles consisting of a metal during processing. Upon impact of the coated particles, the shells provide a reserve of ductility with respect to the behavior of the coated particles, and therefore the deformation of the shells ensures improved incorporation of the particles into the layer which forms. This has the advantage that the concentration range of the particles containing the blowing agent can be varied within a relatively large range in the layer which forms.
  • Cold spraying is a method which is known per se, in which particles intended for the coating are accelerated, preferably to supersonic speed, by means of a convergent-divergent nozzle, so that they remain adhering to the surface to be coated on account of their impressed kinetic energy.
  • the kinetic energy of the particles is utilized, leading to plastic deformation thereof, with the coating particles being melted merely at their surface during impact. Therefore, this method, compared to other thermal spraying methods, is referred to as cold spraying because it is carried out at relatively low temperatures, at which the coating particles remain substantially solid.
  • a cold spraying plant having a gas heating device for heating a gas is preferably used for the cold spraying, which is also termed kinetic spraying.
  • a stagnation chamber is connected to the gas heating device and, at the outlet side, is connected to the convergent-divergent nozzle, preferably a Laval nozzle.
  • Convergent-divergent nozzles have a convergent partial portion and also a divergent partial portion, these being connected by a nozzle neck.
  • the convergent-divergent nozzle generates a powder jet in the form of a gas stream with particles located therein at high speed, preferably supersonic speed.
  • aluminum, copper, nickel, iron, steel or silver are used as materials for the shell. These materials are advantageously very ductile, and therefore when selecting these materials the proportion of particles containing the blowing agent can advantageously be chosen to be very high. In the case of less ductile materials, too, it is possible according to the invention for the range of variation of the possible proportion of particles containing the blowing agent to be increased, a range of variation of between 0 and 100% not being achieved in these cases. With the available ductile materials, however, it is already possible to manage diverse design tasks.
  • aluminum can be used to produce metal foams for lightweight construction. This metal has a low density in any case, but can be used, through the formation of pores, for producing still lighter components.
  • Copper and silver advantageously have a high thermal and electrical conductivity. These materials can therefore be used, for example, as heat exchanger materials, the pores being suitable for forming inner channel structures for the passage of a fluid which is to be heated or cooled.
  • Iron and steel are common construction materials which are additionally inexpensive. They can be used to produce various structural components, it being possible for the lubricating properties to be improved, for example, by a lubricant in the pore systems which have formed.
  • the material of the shell is the same as the material of the exclusively metal-containing particles.
  • the material of the shell is, as it were, incorporated into said metallic matrix. This is not absolutely necessary, however.
  • the material of the shells it would also be possible for the material of the shells to be a catalytically active material, which is deposited into the pore surfaces during the formation of the metal foam.
  • the exclusively metal-containing particles would be merely the support for such a catalytic structure. This structure could be utilized catalytically for the formation of an open metal foam (more details are provided herein below in relation to the possibilities for producing open and closed metal foams).
  • the material of the core is a metal hydride, in particular magnesium hydride or titanium hydride, or a carbonate, in particular calcium carbonate or magnesium carbonate.
  • These blowing agents are common blowing agents for producing metal foams. They provide an expedient temperature range when they are activated, and therefore it is possible to select a suitable blowing agent depending on the softening temperatures of the metallic matrix. This is possible with the aid of general knowledge in the art and, for example, in consultation with the aforementioned documents U.S. Pat. No. 6,464,933 B1 and U.S. Pat. No. 7,402,277 B2.
  • the mixing ratio between the particles containing the blowing agent and exclusively metal-containing particles is varied during the coating process.
  • the density of the pores by suitably setting the mixing ratio in the boundary layer adjacent to the substrate, i.e. the layer proportion lying directly on the substrate, and/or in the boundary layer close to the surface, i.e. the layer proportion which is involved in the formation of the surface, only the metal-containing particles are processed.
  • This has the advantage that a pore-free surface of the layer can be produced and also a boundary layer to the substrate with few pores can be produced.
  • the surface properties of the layer can be influenced in the desired way and it is possible to maximize the adhesion between the layer and the substrate.
  • the density of the pores in the boundary layer adjacent to the substrate is maximized by processing only the particles containing blowing agent. This has the effect that, during the formation of the metal foam, the adhesion of the layer on the substrate is largely abolished. After the metal foam has been produced, the layer can therefore be detached from the substrate without any problems.
  • the substrate makes its surface available merely as the basis for producing an independent component in the form of the layer.
  • a self-supporting, independent component is from the layer.
  • this can be a heat-exchanger plate, the mass of which can advantageously be optimized by detaching the substrate after the metal foam has been produced.
  • the metal foam is produced by a heat treatment of the layer which follows the conclusion of the coating process.
  • the layer is firstly finished and then a heat treatment is carried out, during which the metal foam is formed.
  • the energy input of the cold spraying is thus too low, and therefore it is not sufficient for activating the blowing agent during the deposition of the layer.
  • This method is preferably suitable for producing closed metal foams. Even given a large proportion of particles containing blowing agent, walls will form between the individual pores on account of the deformation of the shells.
  • Another possibility consists in the fact that the energy input during the cold spraying and/or an energy input into the substrate are chosen to be so high that the particles containing the blowing agent are heated to a temperature above the reaction temperature of the blowing agent when they impact on the substrate.
  • the energy input during cold spraying can be increased, for example, by preheating the blowing agent. This is then transferred to the particles to different degrees by a different residence period of the particles in the stagnation chamber connected upstream of the cold spraying nozzle. If the heat input into the particles containing the blowing agent and into the particles consisting exclusively of metal is to be different, it is thus possible to choose the feed-in points of these particles in the stagnation chamber to be at a different distance from the cold spraying nozzle.
  • Two different feed-in points for the particles containing the blowing agent and the exclusively metallic particles is advantageous in any case if the concentration of the particles containing the blowing agent is to be varied.
  • an independent feed of both particle types is namely advantageous, since powders with various mixing ratios do not have to be attained.
  • the energy input into the substrate can be effected, for example, by preheating the latter.
  • Another possibility consists in locally heating the substrate (and the substrate provided with the layer located in the structure) by irradiating the point of impact of the cold gas jet with a laser beam.
  • the additional energy input has the effect that the blowing agent is already activated upon impact of the particles containing the blowing agent on the substrate.
  • the metal pores form, as it were, in situ and increase the porosity of the substrate, i.e. the formation of pores, at the points of impact of said particles. Since, in this case, the pores are formed at the time of great plastic deformation of the particles, the shells of the particles containing the blowing agent are destroyed during the reaction.
  • inventions provide a method for producing the coated particles, wherein said particles are produced from cores consisting of a blowing agent by surrounding these cores with shells consisting of a metal.
  • the coating of the cores with the shell can advantageously be carried out using an electroless electrochemical method. These methods are generally known.
  • a substrate 11 is coated by means of a cold spraying installation 12 .
  • a stagnation chamber 13 and a convergent-divergent nozzle 14 connected to the stagnation chamber are shown by way of example.
  • the nozzle 14 produces a cold gas jet 15 , with which particles 16 are deposited on the substrate 11 , as a result of which the layer 17 is formed.
  • the substrate 11 is preheated by a heating system 18 .
  • a laser 21 directs a laser beam 19 onto the point of impact of the cold gas jet 15 .
  • the carrier gas it is also possible for the carrier gas to be preheated in the stagnation chamber 13 by means of a heating system 20 .
  • FIG. 2 shows the layer 17 in a cut form. It can be seen that particles 22 consisting exclusively of a metal and also coated particles 23 comprising a core 24 consisting of a blowing agent and a shell consisting of the metal are deposited on the substrate 11 . After the cold spraying of the layer, the coated substrate is subjected to a heat treatment, during which the blowing agent of the cores 24 is activated. The layer which results after the heat treatment can be seen in FIG. 3 . It can be seen that pores 26 have formed in the metallic matrix of the layer 17 . This gives rise to a metal foam.
  • the particles 23 containing the blowing agent are distributed uniformly over the entire layer thickness.
  • pores are also formed here in the marginal region of the layer. This means that pores can form an interface with the surface of the substrate 11 , as can be identified in the case of the pore 26 a. It is also possible for the pores to be open with respect to the surface 27 of the layer, as can be identified in the case of the pore 26 b.
  • the layer 17 is deposited in three stages. In stage I, only metallic particles 22 are deposited. In stage II, a mixture of particles 23 containing the blowing agent and metallic particles 22 is deposited. In stage III, only metallic particles 22 are again deposited.
  • the surface 27 and also an interface 28 with the substrate 11 are pore-free owing to deposition phases I and III.
  • the adhesion of the layer 17 on the substrate 11 is therefore not impaired by the pores 26 , just like the surface quality of the surface 27 of the layer 17 .
  • phase II as shown in FIG. 4 , particles 23 containing blowing agent have been deposited in such a low concentration that the pores 26 which form are self-contained, i.e. that these pores are surrounded completely by the matrix material of the layer 17 . This gives rise to a closed-pore metal foam.
  • the layer 17 is deposited in two phases I, II, which correspond to phases I, II as shown in FIG. 4 .
  • Phase III is dispensed with, however, and therefore the surface of the layer deposited as shown in FIG. 6 is partially also formed by particles 23 containing the blowing agent.
  • the particles containing the blowing agent are larger than the metallic particles 22 . If one considers, then, the resulting layer as shown in FIG. 7 after the heat treatment, it can be seen that the particles 23 containing the blowing agent have had the effect, on account of their higher concentration and their size, that common pores have been formed. The shells 25 have been destroyed in the process.
  • phase III has been dispensed with in the deposition, the openings of the pores 26 are also located in part in the surface 27 , giving rise to an open-pore metal foam in the layer 17 , the channels being accessible from the surface 27 .
  • a liquid lubricant can be introduced into these pores, for example.
  • Another possibility would be the introduction of catalytic particles (not shown).
  • the layer 17 is deposited in four phases.
  • the concentration of the particles 23 containing the blowing agent is shown schematically in hatched form over the layer thickness.
  • phase III a gradient layer is produced by increasing the concentration of the particles 23 containing blowing agent from 0 to 80% and then reducing it back to 0%.
  • the layer which results after the heat treatment can be seen in FIG. 9 .
  • the deposition of particles containing blowing agent in phase I has the effect that the layer 17 detaches from the substrate 11 during the heat treatment. This gives rise, as it were, to a single large pore between the layer and the substrate.
  • the layer 17 thus represents an independent plate-shaped component after the heat treatment. This could be used, for example, as a heat-exchanger plate.
  • Phases II and IV have the effect that this plate-shaped component has a closed surface.
  • the end concentration of 80% of particles containing blowing agent in the gradient layer deposited in phase III has the effect that an open-pore channel system has formed in the interior of the layer 17 , this channel system more or less providing a cohesive cavity and being supported by columnar structures 29 . This channel system could be used for the passage of a fluid which is to exchange heat with another fluid beyond the surfaces 27 of the layer 17 .
  • a particle 23 is produced, by way of example, in a bath 30 by the electroless deposition of the shell 25 on the core 24 .
  • the electroless deposition of metals is known per se.
  • copper or nickel can be deposited by an electroless method.
US14/892,073 2013-05-31 2014-05-02 Method For Producing A Metal Foam And Method For Producing Particles Suitable For Said Method Abandoned US20160090653A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102013210198.8A DE102013210198A1 (de) 2013-05-31 2013-05-31 Verfahren zum Herstellen eines Metallschaums sowie Verfahren zum Herstellen von für das vorgenannte Verfahren geeigneten Partikeln
DE102013210198.8 2013-05-31
PCT/EP2014/059000 WO2014191155A1 (de) 2013-05-31 2014-05-02 Verfahren zum herstellen eines metallschaums sowie verfahren zum herstellen von für das vorgenannte verfahren geeigneten partikeln

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EP (1) EP2981380A1 (de)
CA (1) CA2913833A1 (de)
DE (1) DE102013210198A1 (de)
WO (1) WO2014191155A1 (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170229273A1 (en) * 2014-08-06 2017-08-10 Siemens Aktiengesellschaft Electric fuse arrangement with a metal foam and method for interrupting an electric current using the fuse arrangement
US20170355018A1 (en) * 2016-06-09 2017-12-14 Hamilton Sundstrand Corporation Powder deposition for additive manufacturing
US10590529B2 (en) * 2015-11-20 2020-03-17 Fourté International, Sdn. Bhd Metal foams and methods of manufacture
US11662300B2 (en) 2019-09-19 2023-05-30 Westinghouse Electric Company Llc Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing
US11898986B2 (en) 2012-10-10 2024-02-13 Westinghouse Electric Company Llc Systems and methods for steam generator tube analysis for detection of tube degradation
US11935662B2 (en) 2019-07-02 2024-03-19 Westinghouse Electric Company Llc Elongate SiC fuel elements

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114535562B (zh) * 2022-02-24 2023-07-14 安徽省新方尊自动化科技有限公司 一种吹气法制备泡沫铝异形件的生产线

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DE19942916A1 (de) * 1999-09-08 2001-03-15 Linde Gas Ag Herstellen von aufschäumbaren Metallkörpern und Metallschäumen
US6464933B1 (en) 2000-06-29 2002-10-15 Ford Global Technologies, Inc. Forming metal foam structures
DE10246454A1 (de) * 2002-10-04 2004-04-15 Rwth Aachen Herstellung beschichteter geschäumter Bauteile und Bauteile mit keramischer oder Hartstoffbeschichtung
US7402277B2 (en) 2006-02-07 2008-07-22 Exxonmobil Research And Engineering Company Method of forming metal foams by cold spray technique
BRPI0711203A2 (pt) * 2006-05-22 2011-03-22 Nanomech Llc nano/micropartìculas não metálicas revestidas com metal seus processos e aplicações
EP2009132A1 (de) * 2007-06-29 2008-12-31 Sulzer Markets and Technology AG Verfahren zur Herstellung einer funktionalen Schicht, Beschichtungsmaterial, Verfahren zu seiner Herstellung sowie funktionale Schicht
DE102010022599B3 (de) * 2010-05-31 2011-12-01 Siemens Aktiengesellschaft Verfahren zur Erzeugung eines geschlossenporigen Metallschaums sowie Bauteil, welches einen geschlossenporigen Metallschaum aufweist
DE102010022598B3 (de) * 2010-05-31 2011-12-01 Siemens Aktiengesellschaft Verfahren zur Erzeugung eines geschlossenporigen Metallschaums sowie Bauteil, welches einen geschlossenporigen Metallschaum aufweist

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11898986B2 (en) 2012-10-10 2024-02-13 Westinghouse Electric Company Llc Systems and methods for steam generator tube analysis for detection of tube degradation
US20170229273A1 (en) * 2014-08-06 2017-08-10 Siemens Aktiengesellschaft Electric fuse arrangement with a metal foam and method for interrupting an electric current using the fuse arrangement
US10590529B2 (en) * 2015-11-20 2020-03-17 Fourté International, Sdn. Bhd Metal foams and methods of manufacture
US20170355018A1 (en) * 2016-06-09 2017-12-14 Hamilton Sundstrand Corporation Powder deposition for additive manufacturing
US11801554B2 (en) 2016-06-09 2023-10-31 Hamilton Sundstrand Corporation Powder deposition for additive manufacturing
US11935662B2 (en) 2019-07-02 2024-03-19 Westinghouse Electric Company Llc Elongate SiC fuel elements
US11662300B2 (en) 2019-09-19 2023-05-30 Westinghouse Electric Company Llc Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing

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WO2014191155A1 (de) 2014-12-04
DE102013210198A1 (de) 2014-12-04
EP2981380A1 (de) 2016-02-10
CA2913833A1 (en) 2014-12-04

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