Fabrication of a Porous Ni-Based Metal with a Multi-pore Structure by a Screen Printing Process
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Porous metals are commonly considered as having relatively excellent characteristics, such as a large surface area, light, lower heat capacity levels, high toughness, and good permeability. Ni alloys have high corrosion resistance, good heat resistance and chemical stability for high-temperature applications. In this study, porous Ni-based metals for hydrogen reformer catalyst support are developed with Ni alloys, in this case Ni–Cr powder (28 μm), NiO powder (2 μm), and a fine Ni powder (< 1 μm). Ni–Cr powders are spread onto Al2O3 substrate by a printing process. Ni-based foam is then placed on the printed powder and a loading plate. These are sintered at 1200 °C under a high vacuum condition. The NiO powder and the fine Ni powder slurry are then screen-printed sequentially on the double structure (NiCr-coated Ni foam). In this study, the fine Ni powder is printed one, three, and five passes. The porous Ni alloys, which have double-pore structure, triple-pore structure and quadruple-pore structure, are fabricated by screen printing processes. With increased stacking of the pore structure, the porosity decreased from 86 to 82%, and the pore sizes decreased from 6.25 to 0.3 μm. The porosity and pore size of the multi-pore structure can be controlled by the size of powder and screen printing process.
KeywordsPorous metal Ni alloy Screen printing Porosity Pore size
This work was supported by the 2017 Research Fund of University of Ulsan (Grant No. 1).
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