Nickel Foam Surface Roughness via Liquid Binding Agent
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Solution Overview
Problem
Existing open-porous metal foam bodies with nickel base alloys have insufficient surface roughness and specific surface area, limiting their effectiveness in separation and filtration processes, particularly in secondary treatment of exhaust gases, and are prone to brittleness and destruction under mechanical and thermal loads.
Innovation Solution
A method involving coating an open-porous nickel or nickel base alloy foam body with a liquid binding agent, followed by deposition of a mixture of powdery nickel base alloy and an organic component with a phase transition temperature above 30°C, and subsequent thermal treatment to create material-fit connections and increase surface roughness and specific surface area, while maintaining porosity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If CVD methods are used to deposit surface coating to increase surface roughness and specific surface area, then separation capability is improved, but technological effort and cost are considerably increasing
Solution Approach 1:
The invention changes the deposition method from CVD (chemical vapor deposition) to a simpler liquid binding agent-based deposition process. This parameter change in the deposition technique reduces technological complexity while still achieving increased surface roughness and specific surface area through the controlled application of binding agent and subsequent thermal treatment
Solution Approach 2:
The invention uses a simple liquid binding agent that can be easily applied and removed, replacing complex CVD equipment and processes. The binding agent serves its purpose during deposition and thermal treatment, then is eliminated, leaving the desired surface structure without requiring expensive or complex deposition equipment
2Area of stationary object
If CVD methods are used to deposit surface coating to increase surface roughness and specific surface area, then separation capability is improved, but uniform coating deposition within the overall open-porous volume cannot be ensured
Solution Approach 1:
The invention uses a liquid binding agent that can penetrate and coat the open-porous structure uniformly through capillary action and fluid dynamics. The liquid nature of the binding agent allows it to distribute evenly throughout the porous volume, ensuring uniform coating deposition that CVD methods cannot achieve
3Area of stationary object
If intermetallic phases or solid solutions are formed on the surface to enlarge specific surface, then surface area is increased, but brittleness increases and mechanical properties deteriorate
Solution Approach 1:
The invention changes the surface modification approach from forming intermetallic phases or solid solutions to using a physical deposition process with liquid binding agent followed by controlled thermal treatment. This parameter change increases surface area through roughness without creating brittle phases, thereby maintaining mechanical properties
Solution Approach 2:
The invention utilizes the existing open-porous foam body structure and enhances it by depositing material that follows the porous topology. The liquid binding agent penetrates the porous structure, and after thermal treatment, creates surface roughness that increases specific surface area while maintaining the underlying mechanical integrity of the foam body
4Strength
If thermal treatment is performed to improve mechanical properties over extended temperature range, then strength is improved, but surface roughness and specific surface area are not sufficiently increased
Solution Approach 1:
The invention merges two processes: deposition of liquid binding agent with subsequent thermal treatment. The deposition step prepares the surface with increased roughness potential, and the thermal treatment both cures the binding agent and further develops the surface structure. This combination achieves both improved mechanical properties and increased specific surface area simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in metal foam bodies with significantly increased surface roughness and specific surface area, enhancing separation capabilities and mechanical properties, reducing brittleness, and allowing for effective use in exhaust gas treatment systems without significant porosity loss.
Implementation Method 1
its temperature of phase transition is at least 30° C., thus the transition from its solid phase into its liquid phase does not take place below the temperature of phase transition
Implementation Method 2
coating an open-porous nickel or nickel base alloy foam body with a liquid binding agent
Implementation Method 3
the binding agent at least the organic portions thereof, as well as the organic component are expelled
Implementation Method 4
a portion of the powder particles of the previously used powdery nickel base alloy is sintered
Data Source
AI summary
The invention relates to a method for fabricating an open-porous metal foam body with a nickel base alloy, to a metal foam body fabricated this way as well as advantageous applications for the separation of specific components and pollutants from fluid flows. On the occasion, according to the set object open-porous metal foam bodies which have improved mechanical properties, and in addition an enlarged specific surface and/or increased surface roughness are to be provided. During fabricating it is proceeded such that an open-porous base foam body made of nickel or a nickel base alloy is coated with a liquid binding agent. Subsequent to this, a mixture of a powdery nickel base alloy and an organic component the temperature of phase transformation of which is at least 30 degrees centigrade from its solid phase to the liquid phase is deposited. The temperature should then be below the respective temperature of phase transformation. By means of thermal treatment the binding agent and the organic component are expelled, a portion of the powder particles is sintered, and a further portion of the powder particles is connected with the surface of the base foam body in a material-fit manner via sintering bridges.