Abstract
This paper reviews the recent development of fabrication methods of porous metals with open-channels. The open-channel metals are fabricated through powder sintering or solidification technique. The template wires are embedded in the sintered or solidified metals, such as aluminum, copper, titanium and its alloys, which are then removed by chemical dissolution or extraction methods. The hole size, hole length and porosity are uniquely controlled by thickness, length and number of template metallic wires, respectively. The pore size ranges from 102 to several 103 μm in diameter. The open-channel metals are characterized by a large aspect ratio of the length to the diameter of the holes in metals. Furthermore, the techniques can fabricate spiral and V-shaped pores in metals. Feasibility and usefulness of each fabrication method are discussed. The methodology for producing the open-channel metals is expected to provide expanded opportunities for application technologies such as functional materials like heat sinks and sound absorbers and light-weight structural materials.
Similar content being viewed by others
References
L.J. Gibson and M.F. Ashby: Cellular Solids, 2nd ed. (Cambridge University Press, Cambridge, UK, 1997).
H. Nakajima: Fabrication, properties and application of porous metals with directional pores. Progr. Mater. Sci. 52, 1091 (2007).
H. Nakajima: Porous Metals with Directional Pores (Springer, Tokyo, Heidelberg, New York, Dordrecht, London, 2013).
H. Nakajima, S.K. Hyun, K. Ohashi, K. Ota, and K. Murakami: Fabrication of porous copper by unidirectional solidification under hydrogen and its properties. Colloids Surf., A 179, 209 (2001).
V. Shapovalov: Formation of ordered gas-solid structure via solidification in metal-hydrogen systems. Mat. Res. Soc. Symp. Proc. 521, 281 (1998).
H. Chiba, T. Ogushi, and H. Nakajima: Heat transfer capacity of lotus-type porous copper heat sink for air cooling. J. Thermal Sci. Technol. 5, 222 (2010).
H. Chiba, T. Ogushi, and H. Nakajima: Development of heat sinks for air cooling and water cooling using lotus-type porous metals. Proceedings of the ASME/JSME 2011 8th Thermal Eng. Joint Conference (AJTEC2011), Hawaii, USA, 2011, p. 1.
J.S. Park, S.K. Hyun, S. Suzuki, and H. Nakajima: Effect of transference velocity and hydrogen pressure on porosity and pore morphology of lotus-type porous copper fabricated by continuous casting technique. Acta Mater. 55, 5646 (2007).
T. Ide, Y. Iio, and H. Nakajima: Fabrication of porous aluminum with directional pores through continuous casting technique. Metall. Mater. Trans. A 43A, 5140 (2012).
Y. Goto: Available at: http://www.osaka-jp.net/osk22-2.htm, 2017 (accessed 16 February 2019).
D. Gillen and D. Moore: Available at: http://www.blueacretechnology.com, 2012 (accessed 3 January 2019).
P.E. Williams and A.D.L. Zouch: Drilling turbine blades. US patent 5222617, 1993.
M. Hakamada, Y. Asao, T. Kuromura, Y. Chen, H. Kusuda, and M. Mabuchi: Processing of three-dimensional metallic microchannels by spacer method. Mater. Lett. 62, 1118 (2008).
M. Hakamada, Y. Asao, T. Kuromura, Y. Chen, H. Kusuda, and M. Mabuchi: Fabrication of copper microchannels by the spacer method. Scripta Mater. 56, 781 (2007).
M. Hakamada, Y. Asao, N. Saito, and M. Mabuchi: Microfluidic flows in metallic microchannels fabricated by the spacer method. J. Micromech. Microeng. 18, 075029 (2008).
P.J. Kwok, S.M. Oppenheimer, and D.C. Dunand: Porous titanium by electro-chemical dissolution of steel space-holders. Adv. Eng. Mater. 10, 820 (2008).
D.J. Jorgensen and D.C. Dunand: Structure and mechanical properties of Ti-6Al-4V with a replicated network of elongated pores. Acta Mater. 59, 740 (2011).
A.J. Neurohr and D.C. Dunand: Shape-memory NiTi with two-dimensional networks of micro-channels. Acta Biomater. 7, 1862 (2011).
T. Haga and H. Fuse: Fabrication of lotus type through-holes using the semisolid condition. Adv. Mater. Process. Tech. 4, 16 (2018).
T. Haga, K. Toyoda and H. Fuse: Effect of casting conditions on fabrication of lotus type holes in ingot cast by core-bar pulling method. Key Eng. Mater. 748, 187 (2017).
T. Haga and H. Fuse: Fabrication of lotus type porous ingots using the core-bar pulling method. Solid State Phenom. 285, 259 (2019).
D. Muto, T. Yoshida, T. Tamai, M. Sawada and S. Suzuki: Fabrication of porous metals with unidirectionally aligned pores by rod-dipping process. Mater. Trans. 60, 544 (2019).
H. Nakajima: Through hole aluminum fabricated by the extraction of lubricated metallic wires. Metall. Mater. Trans. A 50A, 5707 (2019).
Juntsu, Available at: https://www.juntsu.co.jp/qa/qa0912.php (accessed 27 January 2019).
P.G. Shewmon: Diffusion in Solids (McGraw-Hill, New York, NY, USA, 1963), pp. 117–122.
T. Iida and R.I.L. Guthrie: The Physical Properties of Liquid Metals (Oxford University Press, Oxford, UK, 1988), pp. 199–225.
H. Mehrer: Diffusion in Solid Metals and Alloys (Springer-Verlag, Berlin, Heidelberg, New York, 1990).
S.K. Hyun, K. Murakami and H. Nakajima: Anisotropic mechanical properties of porous copper fabricated by unidirectional solidification. Mater. Sci. Eng., A A299, 241 (2001).
S.K. Hyun and H. Nakajima: Anisotropic compressive properties of porous copper by unidirectional solidification. Mater. Sci. Eng., A A340, 258 (2003).
I. Gibson, D.W. Rosen, and B. Stucker: Additive Manufacturing Technologies (Springer, New York, Heidelberg, Dordrecht, London, 2010).
Acknowledgments
The present author expresses his appreciation to Prof. David Dunand of Northwestern University for useful suggestions on denomination of open-channel metals.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Nakajima, H. Open-channel metals fabricated by the removal of template wires. Journal of Materials Research 35, 2535–2546 (2020). https://doi.org/10.1557/jmr.2020.143
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1557/jmr.2020.143