Lost carbonate sintering process for manufacturing metal foams

Zhao, Yuyuan; Fung, T.; Zhang, L.P.; Zhang, F.L.

doi:10.1016/j.scriptamat.2004.10.012

Cited by 160 publications

(84 citation statements)

References 6 publications

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“…The porosity of the coating can be reduced by controlling the sintering time and temperature to achieve the desired porosity [9]. In order to increase the porosity beyond the native packing density, the most commonly used method is lostcarbonate sintering (LCS) [29]. A mixture of spherical metal particles, carbonate, and a binder is sintered at high temperature under pressure until the carbonate decomposes or melts, leaving behind a porous metal coating.…”

Section: Fabrication Of Test Surfacesmentioning

confidence: 99%

“…The assembly is then allowed to cool gradually. This sintering recipe was selected because it has been shown to produce a clean and well-bonded porous structure for the desired porosity range, and does not require any postprocessing to remove the potassium carbonate from the sintered matrix [29]. Table 1 shows the coating porosity and thickness after the sintering procedure for all the samples fabricated.…”

Section: Fabrication Of Test Surfacesmentioning

confidence: 99%

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Quantitative Evaluation of the Dependence of Pool Boiling Heat Transfer Enhancement on Sintered Particle Coating Characteristics

Sarangi

Weibel

Garimella

2016

Journal of Heat Transfer

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Immersion cooling strategies often employ surface enhancements to improve the pool boiling heat transfer performance. Sintered particle/powder coatings have been commonly used on smooth surfaces to reduce the wall superheat and increase the critical heat flux (CHF). However, there is no unified understanding of the role of coating characteristics on pool boiling heat transfer enhancement. The morphology and size of the particles affect the pore geometry, permeability, thermal conductivity, and other characteristics of the sintered coating. In turn, these characteristics impact the heat transfer coefficient and CHF during boiling. In this study, pool boiling of FC-72 is experimentally investigated using copper surfaces coated with a layer of sintered copper particles of irregular and spherical morphologies for a range of porosities (∼40–80%). Particles of the same effective diameter (90–106 μm) are sintered to yield identical coating thicknesses (∼4 particle diameters). The porous structure formed by sintering is characterized using microcomputed tomography (μ-CT) scanning to study the geometric and effective thermophysical properties of the coatings. The boiling performance of the porous coatings is analyzed. Coating characteristics that influence the boiling heat transfer coefficient and CHF are identified and their relative strength of dependence analyzed using regression analysis. Irregular particles yield higher heat transfer coefficients compared to spherical particles at similar porosity. The coating porosity, pore diameter, unit necking area, unit interfacial area, effective thermal conductivity, and effective permeability are observed to be the most critical coating properties affecting the boiling heat transfer coefficient and CHF.

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Section: Fabrication Of Test Surfacesmentioning

confidence: 99%

Section: Fabrication Of Test Surfacesmentioning

confidence: 99%

Quantitative Evaluation of the Dependence of Pool Boiling Heat Transfer Enhancement on Sintered Particle Coating Characteristics

Sarangi

Weibel

Garimella

2016

Journal of Heat Transfer

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“…In the design of heat exchangers with porous metals, two key properties are important: the heat transfer coefficient and the pressure drop across the sample, [3] which are strongly affected by the pore structure. [4] Porous copper manufactured by the space holder methods, such as the Lost Carbonate Sintering (LCS) process, [5] is a promising type of material for use as heat exchangers. [6] However, there is a very limited amount of data available on the fluid flow and the heat transfer behavior of this type of materials.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Heat Transfer in Porous Metals for Cooling Applications

Avalos-Gauna

Zhao

2017

Metall Mater Trans B

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Porous metals have low densities and novel physical, mechanical, thermal, electrical, and acoustic properties. Hence, they have attracted a large amount of interest over the last few decades. One of their applications is for thermal management in the electronics industry because of their fluid permeability and thermal conductivity. The heat transfer capability is achieved by the interaction between the internal channels within the porous metal and the coolant flowing through them. This paper studies the fluid flow and heat transfer in open-cell porous metals manufactured by space holder methods by numerical simulation using software ANSYS Fluent. A 3D geometric model of the porous structure was created based on the face-centered-cubic arrangement of spheres linked by cylinders. This model allows for different combinations of pore parameters including a wide range of porosity (50 to 80 pct), pore size (400 to 1000 lm), and metal particle size (10 to 75 lm). In this study, water was used as the coolant and copper was selected as the metal matrix. The flow rate was varied in the Darcian and Forchheimer's regimes. The permeability, form drag coefficient, and heat transfer coefficient were calculated under a range of conditions. The numerical results showed that permeability increased whereas the form drag coefficient decreased with porosity. Both permeability and form drag coefficient increased with pore size. Increasing flow rate and decreasing porosity led to better heat transfer performance.

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“…One important property exhibited by porous metals are their strength to weight ratio which can also be exploited in an energy absorption and sound control system environment at minimum cost (Aly, 2007;Salimon et al, 2005) Most of the metal foams in the market are closed aluminum foam which are produced by semi liquid and liquid forming process (Aly, 2007;Salimon et al, 2005;Zhao et al, 2005). Various techniques have been used to produce porous metals and Powder Metallurgy (PM) method is one of them.…”

Section: Introductionmentioning

confidence: 99%

Dissolution Sintering Technique to Create Porous Copper with Sodium Chloride Using Polyvinyl Alcohol Solution through Powder Metallurgy

Waters¹,

Ajinola²,

Salih³

2016

American Journal of Engineering and Applied Sciences

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Abstract:The main purpose of this paper was to investigate the relative densities, porosities, compression strength and energy absorbed by porous copper (Cu) formed via the dissolution sintering technique using Polyvinyl Alcohol (PVA) solution as a binder with Sodium Chloride (NaCl) as space holder. Porous Cu was fabricated through powder metallurgy route using dissolution sintering technique by mixing Cu with NaCl in the volume ratio of 1:1, 1:2, 1:3 and 1:4 and adding PVA solution as binder. The mixture was poured into a press die of 1inch internal diameter and a pressure of 375MPa was applied by a 4 column hydraulic press to create the green form. The NaCl was leached out in hot water at 70°C and then sintered to a temperature of 850°C. Porosity values were determined from density measurements to give the porosity values of 42.2, 44.87, 45.71 and 57.79% for volume ratio of 1:1, 1:2, 1:3, 1:4 respectively. Compression tests were also performed. The results of various plots were used in determining the energy absorbed per unit volume of value of 9.637 MJ/m 3 , 0.750 MJ/m 3 , 0.167 MJ/m 3 , 0.109 MJ/m 3 and the compressive strength of 40 MPa, 3.75, 0.72 MPa, 0.26 MPa for volume ratio of 1:1, 1:2, 1:3 and 1:4 respectively. Scanning Electron Microscope (SEM) was used to characterize the morphology of the pure Cu, the NaCl and the resulting porous Cu.

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Lost carbonate sintering process for manufacturing metal foams

Cited by 160 publications

References 6 publications

Quantitative Evaluation of the Dependence of Pool Boiling Heat Transfer Enhancement on Sintered Particle Coating Characteristics

Quantitative Evaluation of the Dependence of Pool Boiling Heat Transfer Enhancement on Sintered Particle Coating Characteristics

Numerical Simulation of Heat Transfer in Porous Metals for Cooling Applications

Dissolution Sintering Technique to Create Porous Copper with Sodium Chloride Using Polyvinyl Alcohol Solution through Powder Metallurgy

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