A sodium-chloride-space-holder process with two-step heat treatment is used to create an open-porous metal foam (e.g., titanium foam) with a high porosity of about 70 to 90 percent for use in load-bearing applications. A mechanically reliable titanium foam is manufactured using a space-holder method containing two-step heat treatment where a sodium chloride powder is first sieved for desired pore size range, mixed with titanium powder, and compacted under pressure at high temperature. An additional heat treatment is applied to further strengthen the chemical bonding between the titanium particles after the removal of sodium chloride in water to create pores. This process uses a pneumatic pressing machine in combination with a furnace under an argon gas to simultaneously apply both the pressure and temperature. The resulting titanium foam is chemically well bonded and has enhanced durability for proper used in structural applications.

A part including a porous structure including cellular pores and formed at least in part by the periodic repetition of a basic pattern, each cellular pore being delimited by a wall, made of a metal or a polymer, having a parietal porosity greater than 5% and including parietal pores with a mean size less than the mean size of the cellular pores.

A metallic filter (1) includes a microstructured architecture (2) defined in a three-dimensional space having orthogonal axes, microstructured architecture (2) includes a metallic network (10) formed by a plurality of longitudinal connecting strands (12), namely extending along a longitudinal axis direction (X), and a network (20) of pores formed of a plurality of longitudinal interstices (22) located along connecting strands (12). Each longitudinal interstice corresponding to a subset of pores (24) of the network (20) of pores. The subset of pores (24) for which the pores are aligned along the longitudinal axis (X), the longitudinal interstices (22) thereby defining an axis of anisotropy of the microstructured architecture.

A metallic filter (1) includes a microstructured architecture (2) defined in a three-dimensional space having orthogonal axes, microstructured architecture (2) includes a metallic network (10) formed by a plurality of longitudinal connecting strands (12), namely extending along a longitudinal axis direction (X), and a network (20) of pores formed of a plurality of longitudinal interstices (22) located along connecting strands (12). Each longitudinal interstice corresponding to a subset of pores (24) of the network (20) of pores. The subset of pores (24) for which the pores are aligned along the longitudinal axis (X), the longitudinal interstices (22) thereby defining an axis of anisotropy of the microstructured architecture.

A metallic filter (1) includes a microstructured architecture (2) defined in a three-dimensional space having orthogonal axes, microstructured architecture (2) includes a metallic network (10) formed by a plurality of longitudinal connecting strands (12), namely extending along a longitudinal axis direction (X), and a network (20) of pores formed of a plurality of longitudinal interstices (22) located along connecting strands (12). Each longitudinal interstice corresponding to a subset of pores (24) of the network (20) of pores. The subset of pores (24) for which the pores are aligned along the longitudinal axis (X), the longitudinal interstices (22) thereby defining an axis of anisotropy of the microstructured architecture.

In a method of manufacturing open-cell bodies, individual parts of an open pore plastic in a size which corresponds to the size of the bodies to be manufactured while taking account of the shrinkage on a sintering or an open pore plastic element having predetermined break points which take account of the size and geometrical design of bodies to be manufactured are/is in filtrated and coated with a suspension in which at least one powdery material is contained. Organic components are expelled after a first heat treatment. Subsequently, a sintering is carried out. Parts of porous plastic provided with the suspension are separated before the first heat treatment or wherein, afterwards the open-cell element which is obtained from the plastic element from the material with which the bodies are formed is cut by forces and thereby separated bodies can be obtained.

A green compact according to the present invention is a green compact, which is obtained by compaction-molding raw material powder containing metal powder as a main raw material, the green compact including an oxide film formed between particles of the raw material powder forming the green compact, the oxide film binding the particles of the raw material powder to each other, in which the metal powder to toe used includes metal powder showing a circularity R at a cumulative frequency of 80% of 0.75 or more, the circularity R being expressed by Equation (1), where S represents a two-dimensional projected area of the metal powder and L represents a two-dimensional projected circumferential length of the metal powder.

[00001]$\begin{array}{cc}R=4.Math.\pi \times \frac{S}{L^2}& \left(1\right)\end{array}$

A method to achieve full densification and grain size control for sintering metal materials, wherein raw material powder is deagglomerated to obtain deagglomerated powder with dispersion. The deagglomerated powder is granulated by spray granulation. The granulated particles are processed by high-pressure die pressing and cold isostatic pressing. The powder compact is sintered by two-step pressureless sintering. The first step is to heat up the powder compact to a higher temperature and hold for a short time to obtain 75-85% theoretical density; the second step is to cool down powder compact to a lower temperature and hold for a long time. The two-step sintering can decrease the sintering temperature, so that the powder compact can be densified at a lower temperature. Thus, the obtained refractory metal product is densified, with ultrafine grains, uniform grain size distribution, and outstanding mechanical properties.

A piece of flexible porous metal foil is a sheet made of porous metal material using solid solution alloy, face-centered cubic metal simple substance or body-centered cubic metal simple substance as matrix phase. The thickness of the sheet is 5 to 200 micrometers, the average aperture thereof is 0.05 to 100 micrometers, the porosity thereof is 15-70%, and the sheet is made by sintering a homogeneous film. The preparation method for the flexible porous metal foil comprises: (1) preparing thick turbid liquid with raw material powder forming the metal porous material by using dispersing agent and binding agent; (2) injecting the turbid liquid into a mold cavity of a film manufacturing fixture, and drying the turbid liquid to form a piece of homogeneous film; (3) putting the film into a sintering manufacturing fixture matching with the film in shape, then sintering the film, and taking the film out after sintering and obtaining the flexible porous metal foil. The flexible porous metal foil made by the above method can be used in many fields, and have ideal performance in flexible and chemical stability.

A piece of flexible porous metal foil is a sheet made of porous metal material using solid solution alloy, face-centered cubic metal simple substance or body-centered cubic metal simple substance as matrix phase. The thickness of the sheet is 5 to 200 micrometers, the average aperture thereof is 0.05 to 100 micrometers, the porosity thereof is 15-70%, and the sheet is made by sintering a homogeneous film. The preparation method for the flexible porous metal foil comprises: (1) preparing thick turbid liquid with raw material powder forming the metal porous material by using dispersing agent and binding agent; (2) injecting the turbid liquid into a mold cavity of a film manufacturing fixture, and drying the turbid liquid to form a piece of homogeneous film; (3) putting the film into a sintering manufacturing fixture matching with the film in shape, then sintering the film, and taking the film out after sintering and obtaining the flexible porous metal foil. The flexible porous metal foil made by the above method can be used in many fields, and have ideal performance in flexible and chemical stability.