Novel polymer-metal based method for open cell metal foams production

Metal foams have acquired popular interest in recent years and are potentia lly useful for many applications due to their light weight, high specific s tiffness, high surface to volume ratio, and adjustable cell structure. Here , current methods of producing metal foams are briefly reviewed. The requir ements for high porosity metal foams with open cells are discussed, A novel powder metallurgy route involving a polymeric vehicle is introduced that c an readily generate open cell foams with porosity greater than 90%. Coarse Ti powder and fine carbonyl iron powder were tested. Although the resulting polymer metal foam was closed cell, particles were not retained in the win dows, Upon pyrolysis to remove the resin, the windows opened and the final sintered metal foam was highly reticulated. Such foams offer a fine reticul ated structure with cell diameters in the region of 100-200 mu m, and may f ind applications in the areas of catalysis, biomaterials, and composites, M ST/4622 (C) 2000 IoM Communications Ltd.