Optimizing the Pore Structure of Lotus-Type Porous Copper Fabricated by Continuous Casting

Abstract

Lotus-type porous copper was fabricated using a continuous casting method in pressurized hydrogen and nitrogen gas atmospheres. This study evaluates the effects of process parameters, such as the hydrogen ratio, total pressure, and transference velocity, on the resulting pore structure. A continuous casting process was developed to facilitate the mass production of lotus-type porous copper. To achieve the desired porosity and pore diameter for large-scale manufacturing, a systematic evaluation of the influence of each process parameter was conducted. Lotus-type porous copper was produced within a hydrogen ratio range of 25–50%, a transference velocity range of 30–90 mm∙min−1, and a total pressure range of 0.2–0.4 MPa. As a result, the porosity ranged from 36% to 55% and the pore size varied from 300 to 1500 µm, demonstrating a wide range of porosities and pore sizes. Through process optimization, it is possible to control the porosity and pore size. The hydrogen ratio and total pressure were found to primarily affect porosity, whereas the hydrogen ratio, transference velocity, and total pressure significantly influenced pore diameter. When considering these parameters together, porosity was most influenced by the hydrogen ratio, whereas the total pressure and transference velocity had a greater influence on pore diameter. Reducing the hydrogen ratio and increasing the transference velocity and total pressure reduced the pore diameter and porosity. This optimization of the continuous casting process enables the control of porosity and pore diameter, facilitating the production of lotus-type porous copper with the desired pore structures.