# US 2021/0276090 A1 · Method for manufacturing metal alloy foam > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0276090 A1 - Document ID: US20210276090A1 - Status: Published application - Kind: A1 - Application number: 16/332,603 - Filed: 2017-10-12 - Published: 2021-09-09 - Earliest claimed: 2016-10-14 - Assignees: LG Chem, Ltd. - Applicants: LG Chem , Ltd. - Inventors: So Jin KIM; Dong Woo YOO; Jin Kyu LEE - Web page: https://patentgrep.com/patent/US20210276090A1 ## CPC - B22F 3/11: Making porous workpieces or articles - B22F 1/10: Metallic powder containing lubricating or binding agents; Metallic powder containing organic material - B22F 3/105: by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} - C22C 1/08: Alloys with open or closed pores - B22F 2003/1053: {by induction} - B22F 2998/10: Processes characterised by the sequence of their steps - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - C22C: ALLOYS (treatment of alloys C21D, C22F) ## Abstract The present application provides a method for manufacturing a metal alloy foam. The present application can provide a method for manufacturing a metal alloy foam, which is capable of forming a metal alloy foam comprising uniformly formed pores and having excellent mechanical properties as well as the desired porosity, and a metal alloy foam having the above characteristics. In addition, the present application can provide a method capable of forming a metal alloy foam in which the above-mentioned physical properties are ensured, while being in the form of a thin film or sheet, within a fast process time, and such a metal alloy foam. ## Claims ### Claim 1 A method for manufacturing a metal alloy foam comprising a step of sintering a green structure comprising a metal component, which comprises a first metal having a relative magnetic permeability of 90 or more and a conductivity at 20° C. of 8 MS/m or more and a second metal different from the first metal. ### Claim 2 (depends on 1) The method for manufacturing a metal alloy foam according to claim 1, wherein the first metal is nickel, iron or cobalt ### Claim 3 (depends on 1) The method for manufacturing a metal alloy foam according to claim 1, wherein the second metal is one or more selected from the group consisting of copper, zinc, manganese, chromium, indium, tin, molybdenum, silver, platinum, gold, aluminum and magnesium. ### Claim 4 (depends on 1) The method for manufacturing a metal alloy foam according to claim 1, wherein the metal component comprises, on the basis of weight, 30 wt % or more of the first metal. ### Claim 5 (depends on 1) The method for manufacturing a metal alloy foam according to claim 1, wherein the metal component has an average particle diameter in a range of 0.1 to 200 μm. ### Claim 6 (depends on 1) The method for manufacturing a metal alloy foam according to claim 1, wherein the green structure is formed using a slurry comprising the metal component containing the first and second metals, a dispersant, and a binder. ### Claim 7 (depends on 6) The method for manufacturing a metal alloy foam according to claim 6, wherein the dispersant is an alcohol. ### Claim 8 (depends on 6) The method for manufacturing a metal alloy foam according to claim 6, wherein the binder is an alkyl cellulose, polyalkylene carbonate or polyvinyl alcohol compound. ### Claim 9 (depends on 6) The method for manufacturing a metal alloy foam according to claim 6, wherein the slurry comprises 10 to 500 parts by weight of the dispersant relative to 100 parts by weight of the metal component. ### Claim 10 (depends on 6) The method for manufacturing a metal alloy foam according to claim 6, wherein the slurry comprises 5 to 200 parts by weight of the binder relative to 100 parts by weight of the metal component ### Claim 11 (depends on 6) The method for manufacturing a metal alloy foam according to claim 6, wherein the slurry comprises 3 to 500 parts by weight of the binder relative to 100 parts by weight of the dispersant. ### Claim 12 (depends on 1) The method for manufacturing a metal alloy foam according to claim 1, wherein the sintering of the green structure is performed by applying an electromagnetic field to the structure. ### Claim 13 (depends on 12) The method for manufacturing a metal alloy foam according to claim 12, wherein the electromagnetic field is formed by applying a current in a range of 100 A to 1,000 A. ### Claim 14 (depends on 12) The method for manufacturing a metal alloy foam according to claim 12, wherein the electromagnetic field is formed by applying a current at a frequency in a range of 100 kHz to 1,000 kHz. ### Claim 15 (depends on 12) The method for manufacturing a metal alloy foam according to claim 12, wherein the electromagnetic field is applied for a time in a range of 1 minute to 10 hours. ### Claim 16 A metal alloy foam comprising an alloy of a first metal having a relative magnetic permeability of 90 or more and a conductivity at 20° C. of 8 MS/m or more and a second metal different from the first metal, and having a porosity in a range of 40% to 99% and a tensile strength of 2.5 MPa or more. ### Claim 17 (depends on 16) The metal alloy foam according to claim 16, wherein the metal alloy foam is in the form of a film or sheet having a thickness of 2,000 μm or less. ### Claim 18 (depends on 6) The method for manufacturing a metal alloy foam according to claim 6, wherein the method comprises drying the green structure prior to the sintering.