Porous metal bodies
AssigneeCorning Glass Works
InventorsKim D. Pierotti, Raja R. Wusirika
Life of this patent
Estimating the term…
Abstract
This invention is concerned with the production of hard, porous, sintered bodies consisting essentially of Al and Fe with, optionally, Sn and/or Cu and/or Cr. The mechanism of the invention relies upon the presence of a small amount of Mg and/or Ca to act as a getter for oxygen. In the preferred embodiment, particles of the metals can be extruded into honeycomb structures which can then be fired in the presence of Mg and/or Ca to yield sound high cell density structures of controlled porosity.
Claims16
A hard, porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20%, at least some and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca.
A hard, porous honeycomb structure having a cell density of at least 10 cells/in.sup.2 with the walls of said cells having a thickness of at least 75 microns, said structure being composed of a material having a porosity of about 25-75% by volume, with pores ranging between about 1-100 microns in size, and consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-40% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than about 1% of a alkaline earth metal selected from the group consisting of Mg and Ca.
A method for producing a hard porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca, which comprises the steps of:
- (a) preparing a homogenous mixture of particulate Al, Fe, and, optionally, Sn, Cu, and Cu in the proper proportions with at least 0.5% particulate alkaline earth metal or an amount of a particulate readily-vaporizable alkaline earth metal compound sufficient to yield at least 0.5% alkaline earth metal in an organic binder/vehicle;
- (b) forming said mixture into a shape of a desired configuration;
- and then
- (c) firing said shape in an essentially non-oxidizing atmosphere to a temperature between about 1000.degree.-1400.degree. C. for a sufficient length of time to vaporize off any excess alkaline earth metal and to sinter the metal particles together into a sound, integral body of desired porosity.
A method for producing a hard porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca, which comprises the steps of:
- (a) preparing a homogenous mixture of particulate Al, Fe, and, optionally, Sn, Cu, and Cr in the proper proportions in an organic binder/vehicle medium;
- (b) forming said mixture into a shape of a desired configuration;
- and then
- (c) firing said shape in an essentially non-oxidizing atmosphere to a temperature between about 1000.degree.-1400.degree. C. in close relation to, but at least partially out of contact with, a source of particulate alkaline earth metal selected from the group of Mg and Ca or a particulate readily-vaporizable alkaline earth metal compound for a sufficient length of time to cause vapors of said alkaline earth metal to contact the particulate Fe and Al and to sinter the metal particles together into a sound, integral body of desired porosity.
Dependencies are inferred from the claim text.