An abradable coating structure with at least partially closed cells made of a metallic material with a mean cell wall porosity between 7 and 50%, in particular between 20 and 40%, a mean cell wall thickness between 50 and 200 m, in particular between 80 and 150 m, a cell size with a mean free diameter between 200 m and 15 mm, in particular 2 mm or in particular between 8 and 12 mm and a mean carbon concentration in the material of between 0 and 5% by weight, in particular between 0.05 and 2% by weight. The invention also relates to a component with a polyhedral cell structure and to a method for manufacturing the polyhedral cell structure.

An abradable coating structure with at least partially closed cells made of a metallic material with a mean cell wall porosity between 7 and 50%, in particular between 20 and 40%, a mean cell wall thickness between 50 and 200 m, in particular between 80 and 150 m, a cell size with a mean free diameter between 200 m and 15 mm, in particular 2 mm or in particular between 8 and 12 mm and a mean carbon concentration in the material of between 0 and 5% by weight, in particular between 0.05 and 2% by weight. The invention also relates to a component with a polyhedral cell structure and to a method for manufacturing the polyhedral cell structure.

A method for the additive manufacturing of a component includes: the additive building up of a structure from a base material for the component by an additive manufacturing method; the introduction, during the additive building up of the structure, of a porous auxiliary structure into an interior of the structure to define a functional area for the component in the interior; and the removing, in particular melting, of the porous auxiliary structure from the functional area by heating the auxiliary structure so that the functional area no longer has the auxiliary structure. A component is produced in accordance with the method and a corresponding device.

Foamable semifinished product (1) in the form of granules produced from the metal alloy and the foam agent is inserted into the cavity of the closable mould (2) and the liquid (3) with the density that is higher than the apparent (or bulk) density of the resulting foam is led to it. The liquid has a temperature which is higher than the temperature of the melting of the metal alloy; the transfer of the heat to the particles of the foamable semifinished product (1) takes place; it subsequently expands, whereby it is supported by the liquid (3). During the expansion at least part of the liquid (3) is pushed by the expansion itself out of the mould (2) through the opening. The liquid (3) allows the regulation of the pressure of the environment of the foam agent, too, which helps to set exactly the moment of expansion. The metal melt can be advantageously used as liquid (3). The melt can partially remain in the mould (2) so the hybrid structure of the component is created. The new method makes the foaming significantly quicker, it secures the homogeneity of the metal foam, simplifies the moulds and diminishes the energy demands for the whole process.

Foamable semifinished product (1) in the form of granules produced from the metal alloy and the foam agent is inserted into the cavity of the closable mould (2) and the liquid (3) with the density that is higher than the apparent (or bulk) density of the resulting foam is led to it. The liquid has a temperature which is higher than the temperature of the melting of the metal alloy; the transfer of the heat to the particles of the foamable semifinished product (1) takes place; it subsequently expands, whereby it is supported by the liquid (3). During the expansion at least part of the liquid (3) is pushed by the expansion itself out of the mould (2) through the opening. The liquid (3) allows the regulation of the pressure of the environment of the foam agent, too, which helps to set exactly the moment of expansion. The metal melt can be advantageously used as liquid (3). The melt can partially remain in the mould (2) so the hybrid structure of the component is created. The new method makes the foaming significantly quicker, it secures the homogeneity of the metal foam, simplifies the moulds and diminishes the energy demands for the whole process.

A method for fabricating a metal foam component from an aerogel containing a polymer and nanoparticles is disclosed. The method may comprise: 1) exposing the aerogel to a reducing condition at an elevated temperature for a reaction time to provide a metal foam; and 2) using the metal foam to fabricate the metal foam component. At least one of the elevated temperature and the reaction time may be selected so that at least some ligaments of the metal foam have a desired ligament diameter or at least some pores of the metal foam have a desired pore size. The desired ligament diameter may be less than about one micron and the component may be a component of a gas turbine engine.

A method for fabricating a metal foam component from an aerogel containing a polymer and nanoparticles is disclosed. The method may comprise: 1) exposing the aerogel to a reducing condition at an elevated temperature for a reaction time to provide a metal foam; and 2) using the metal foam to fabricate the metal foam component. At least one of the elevated temperature and the reaction time may be selected so that at least some ligaments of the metal foam have a desired ligament diameter or at least some pores of the metal foam have a desired pore size. The desired ligament diameter may be less than about one micron and the component may be a component of a gas turbine engine.

A device including a first portion made of a first material and a second portion made of a second material, the second part extends from one of faces of the first portion and is made of an amorphous material.

A method of fabricating a structure having an open cell foam element includes providing an open cell foam element of metallic, diamond, ceramic and/or refractory material form, and/or having one or more metallic, diamond, ceramic and/or refractory material coatings, the foam element defining a plurality of interconnected cells. The method further includes locating a material within the cells, and treating the material, in situ, by sintering and/or infiltration, to form a continuous mesh or lattice structure that extends within and through the cells of the open cell foam element. Structures fabricated using the method are also described.

A mixed material having a high expansion rate for producing a porous metallic sintered body including: a conventional mixed material for producing a porous metallic sintered body which is formed of a mixture including a composition of 0.05 to 10% by mass of a non-water-soluble hydrocarbon-based organic solvent having 5 to 8 carbon atoms, 0.5 to 20% by mass of a water-soluble resin binder, and 5 to 80% by mass of a metal powder having an average particle size within a range of 0.5 to 500 m, and water as the balance; and a gas, wherein the mixed material contains the gas so that the proportion of the gas is within a range of 2 to 50% by volume while the remainder is the conventional mixed material for producing a porous metallic sintered body.