Multi-channel structures and processes for making structures usi

Details Multi-channel structures and processes for making structures usi Multi-channel structures and processes for making structures usi

1996-11-06

1999-01-26

Jenkins, Daniel J.

Powder metallurgy processes

Powder metallurgy processes with heating or sintering

Making porous product

419 3, 419 4, 419 37, 419 41, 419 45, 419 54, 419 55, 264 56, 264 59, 264 63, 501 81, 501 95, 501 99, 428550, B22F 702

Patent

active

058647430

ABSTRACT:
A method for making multi-channel structures suitable for use as filters, catalyst carriers or the like. A composite rod comprising an outer shell and an inner core is formed of respective mixtures of powders. The mixture for the outer shell comprises a sinterable powdered structural material such as ceramics, metals, intermetallics, and a powdered binder. The inner core comprises a powdered carbon channel-forming filler material such as graphite or amorphous carbon, and a powdered binder. The composite rod may be deformed, as by extrusion, to reduce its diameter. A bundle of composite rods is assembled and deformed, as by extrusion, to reduce the diameter of the bundle and of its component composite rods. Further bundles of the reduced diameter bundles of composite rods may be likewise deformed by extrusion to reduce further the diameter of the component composite rods of the successive bundles, thereby also increasing the number of such rods per given cross section area of the bundle. The final assembly of bundles is consolidated and the binder is removed, as by heating, followed by removal of the carbon inner cores of the composite rods of the assembly of bundles by oxidation and sintering of the remaining structure of ceramic or metal, as the case may be.

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patent: 5181549 (1993-01-01), Shapovalov
Jones, "Fundamental Principles of Powder Metallurgy," Edward Arnold Publishers Ltd., London, 1960 pp. 340-341.
Zheng et al., "Controlled Porosity Alloys Through Solidification Processing: A Modelling Study, " Materials Research Society Symposium Proceedings, vol. 371, Advances in Porous Materials, Pittsburgh, PA. Dec. 1994 pp. 365-370.
Pattnaic et al., "Microstructure of Gasar Porous Ingot," Materials Research Society Symposium Proceedings, vol. 371, Advances in Porous Materials, Pittsburgh, PA, Dec. 1994 pp. 371-376.
Wolla et al, "Mechanical Properties of Gasar Porous Copper," Materials Research Society Symposium Proceedings, vol. 371, Advances in Porous Materials, Pittsburgh, PA, Dec. 1994, pp. 377-382.

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