多孔不锈钢的制备及其在注塑模具中的应用

通过凝胶注模与微波烧结方法制备多孔不锈钢,研究粉末固相含量对浆料和生坯性能的影响,比较冷冻干燥与传统干燥的效果,对比本文制备的多孔不锈钢与PM35多孔模具钢的内部孔隙与宏观性能,并将其用于注塑模型芯。实验结果表明:粉末固相含量为56%时,浆料流动性好,生坯强度高;与传统干燥方法相比,冷冻干燥后的生坯收缩更均匀,不易产生裂纹;与PM35多孔模具钢相比,本文制备的多孔不锈钢具有相近的孔隙形貌、孔隙率、平均孔径和透气率;利用多孔不锈钢型芯制作的注塑件表面粗糙度可达Ra1.1。凝胶注模与微波烧结法制备的多孔不锈钢可以很好地解决困气问题,同时保证注塑件的表面质量,简化模具结构,降低生产成本。     

凝胶注模成型法制备多孔羟基磷灰石陶瓷

采用凝胶注模成型工艺制备了多孔羟基磷灰石陶瓷,并通过X射线分析了多孔陶瓷的相成分,采用扫描电镜观测了孔隙结构和形貌.结果表明,所制备的多孔羟基磷灰石陶瓷的孔隙率均大于80%;孔隙尺寸主要分布在350～600μm,孔壁上存在孔径为60～190μm的贯通孔;X射线衍射证明烧结过程未引入异质成分.所制备的多孔羟基磷灰石陶瓷具有适宜的孔隙直径和孔隙率,且孔隙间具有良好的贯通性.     

凝胶注模成形法制备多孔铝及其性能研究

为了开发多孔铝制备新工艺与提高性能,采用凝胶注模法制备了形状较复杂的多孔铝。探讨了固相含量和烧结温度对多孔铝的密度、孔隙率、显微结构及力学性能的影响。结果表明,随固相含量的增加,烧结体密度随之增大,抗压缩性能提高;在不添加烧结助剂的条件下,680℃为最佳烧结温度。制得的多孔铝为开孔结构,孔隙率在34%～53%间可调,平均孔径3.82μm,抗压强度76.8MPa,比表面积0.12m2/g。     

造孔剂法制备硅藻土基多孔陶瓷及其性能研究

以硅藻土和烧结助剂为原料、聚苯乙烯(PS)为有机造孔剂,采用热压铸工艺,在1 150℃/2 h条件下制备了孔隙率为50%～60%的硅藻土多孔陶瓷,分别研究烧结助剂含量、造孔剂粒径及含量对多孔陶瓷孔隙率、孔径和微观结构的影响,进一步研究多孔陶瓷的孔隙率、孔径与陶瓷平均吸油速率的关系。结果表明：当硅藻土粒径为25μm、烧结助剂含量为13%(质量分数,下同),造孔剂粒径为30μm且添加含量为20%时,制备的多孔陶瓷的开放孔隙率可高达60%;平均吸油速率随多孔陶瓷孔径和孔隙率增大而提高,其中孔径的影响更大,当孔径由9.3μm增大到28.8μm时,平均吸油速率由1.1 mg/s提高到3.6 mg/s。     

孔隙率对钛合金生物医用材料耐蚀性的影响

通过凝胶注模工艺制备不同孔隙率的多孔钛合金(Ti-17.5Mo),采用扫描电子显微镜、X射线衍射对多孔钛合金表面形貌和孔隙率的变化进行了分析。通过测量Ti-17.5Mo合金的极化曲线、交流阻抗,对其在模拟体液(SBF)中的耐腐蚀性进行了探讨研究。结果表明,随着固含量的增加,烧结后凝胶注模制备的坯体孔隙率随之降低,使得试样在模拟体液中的阻挡层容抗强度和阻抗强度增加。水基凝胶注模Ti-17.5Mo体系固含量可以达到35%,烧结后孔隙率可以降到42%,电化学耐蚀性最好。     

凝胶注模法制备多孔碳化硅支撑体

以大颗粒碳化硅(SiC)为陶瓷骨料,采用凝胶注模法制备支撑体生坯,原位反应烧结制备大孔径、高渗透性的多孔SiC陶瓷支撑体,主要考察了有机单体含量和烧结制度对高温气固分离用陶瓷膜支撑体性能的影响.研究结果表明:适宜的有机单体含量有助于SiC颗粒稳定分散在悬浮液中,提高烧结温度和延长保温时间均可增加SiC颗粒的氧化程度,在1 550℃时,XRD图谱显示莫来石相生成,支撑体的抗弯强度有一定程度的提高.采用凝胶注模法制备的生坯在1 550℃,保温4h烧结后具有良好的性能:抗弯强度为20.4 MPa,孔隙率为37%,平均孔径为23μm,气体渗透率为2.01×10-12 m2.     

粉末冶金法制备多孔金属钛免疫隔离材料

采用粉末冶金工艺制备出微米孔径且孔隙率较高的多孔钛免疫隔离材料，分析了压制压力、烧结温度等因素对多孔金属钛孔径及孔隙率的影响。试验结果表明，随着压制压力的提高，钛粉末烧结后平均孔径尺寸和孔隙率逐渐减小，孔隙分布和孔径尺寸较均一。烧结温度对多孔金属钛影响显著，随烧结温度的升高，平均孔径尺寸逐渐增大，孔隙率先略有上升后逐渐降低。     

多孔Al-Si12合金的制备与性能研究

采用真空—压力烧结—溶解工艺制备出了孔隙率44%～76%、平均孔径30～110μm的多孔Al-Si12合金,对多孔Al-Si12合金的制备、孔结构、抗弯强度及渗透性能进行了研究。结果表明,真空环境下的压力烧结可明显提高多孔Al-Si12合金的抗弯强度,最佳的制备工艺为压制压力500MPa、烧结温度565℃、烧结时间2h以及烧结压力150～200MPa;多孔Al-Si12合金的相对渗透系数随其孔隙率和平均孔径的提高而增大;多孔Al-Si12合金的抗弯强度高于相近孔结构的多孔铝,渗透性能优于相近孔结构的多孔不锈钢及多孔铝。     

多孔Ni-Mn-Ga-Co磁性形状记忆合金的制备及磁学特性研究

首先采用球磨法制备了不同粒度的Ni-Mn-Ga-Co合金粉末,然后通过3D打印技术成功制备了泡沫结构的多孔Ni-Mn-Ga-Co磁性形状记忆合金。利用SEM、DSC和XRD等研究了合金的微观组织特征、物相结构、相变特性和相关的磁性行为。结果表明,球磨后经过分筛得到的不同粒径尺寸的合金粉末均为不规则形状。Ni-Mn-Ga-Co合金粉末在室温下为非调制四方马氏体结构,其特征峰十分明显。Ni-Mn-Ga-Co合金的DSC曲线上出现宽峰相变,添加Co元素对马氏体转变温度开始值(Ms)基本没有影响,但其居里温度(Tc)有显著的提高。采用粒径为50~100μm的合金粉末烧结制备的磁性合金,饱和磁化强度最大可达68 Am^2/kg。合金粉末粒径越小,烧结制备的多孔Ni-Mn-Ga-Co磁性形状记忆合金致密度越高。当合金粉末粒径<50μm时,致密度可达90%;当合金粉末粒径为50~100μm时,致密度仅为75%。相较于粒径较小的合金粉末,粒径较大的合金粉末制备的磁性合金磁感生应变能力更高,这是由于泡沫结构能够有效减少内部和外部的约束,从而有利于提高磁场诱导应变。     

凝胶注模常温发泡制备氧化铝多孔陶瓷

以高纯氧化铝为原料,通过起泡结合凝胶注模成型的方法制备了孔隙率为77%～85%、孔径为40～200μm的氧化铝多孔陶瓷.多孔陶瓷组成为α-Al2O3.多孔陶瓷的微结构可通过固含量与发泡剂加入量的改变进行调控.多孔陶瓷的耐压强度为9.40～32.50MPa,且对其断裂方式进行了研究.多孔陶瓷在1000℃下的热导率为0.80 W.(m.K)-1.     

添加成孔剂法制备孔径、气孔率可控的多孔玻璃陶瓷

研究了采用添加成孔剂法制备具有相互贯通气孔的多孔生物玻璃陶瓷的方法及其性能.多孔玻璃陶瓷主晶相为氟磷灰石和β-硅灰石,气孔率在49％-82％间连续可控,气孔由成孔剂热解排除形成的球形宏观孔(孔径200-850μm)和玻璃粉体烧结形成的微观孔(孔径2-4μm)组成,宏观孔孔径取决于成孔剂粒径并通过孔壁上的孔洞(孔径50-300μm)相互连通.塑性成孔剂硬脂酸受压产生塑性变形,添加硬脂酸的素坯强度高、可加工,烧结产物强度较高、气孔为扁球状;刚性成孔剂聚苯乙烯受压产生弹性变形,添加聚苯乙烯的素坯疏松、不可加工,烧结产物强度较低、气孔呈圆球状.成形压力对添加塑性成孔剂的样品性能影响显著,而对添加刚性成孔剂的样品性能无显著影响.气孔率与成孔剂的含量成良好的线性关系,通过控制成孔剂粒径和加入量可达到气孔率、孔径可控的目的.孔径一定时抗压强度与总气孔率成良好的二次曲线关系.     

Hydroxyapatite scaffolds processed using a TBA-based freeze-gel casting/polymer sponge technique

A novel freeze-gel casting/polymer sponge technique has been introduced to fabricate porous hydroxyapatite scaffolds with controlled “designer” pore structures and improved compressive strength for bone tissue engineering applications. Tertiary-butyl alcohol (TBA) was used as a solvent in this work. The merits of each production process, freeze casting, gel casting, and polymer sponge route were characterized by the sintered microstructure and mechanical strength. A reticulated structure with large pore size of 180–360 μm, which formed on burn-out of polyurethane foam, consisted of the strut with highly interconnected, unidirectional, long pore channels (~4.5 μm in dia.) by evaporation of frozen TBA produced in freeze casting together with the dense inner walls with a few, isolated fine pores (<2 μm) by gel casting. The sintered porosity and pore size generally behaved in an opposite manner to the solid loading, i.e., a high solid loading gave low porosity and small pore size, and a thickening of the strut cross section, thus leading to higher compressive strengths.     

Fabrication of Lotus‐type Porous Metals and their Physical Properties

Lotus‐type porous metals whose long cylindrical pores are aligned in one direction were fabricated by unidirectional solidification in a pressurized gas atmosphere. The pores are formed as a result of precipitation of supersaturated gas when liquid metal is solidified. The lotus‐type porous metals with homogeneous size and porosity of the evolved pores produced by a mould casting technique are limited to the metals with high thermal conductivity. On the other hand, the pores with inhomogeneous pore size and porosity are evolved for metals and alloys with low thermal conductivity such as stainless steel. In order to obtain uniform pore size and porosity, a new “continuous zone melting technique” was developed to fabricate long rod‐ and plate‐shape porous metals and alloys even with low thermal conductivity. Mechanical properties of tensile and compressive strength of lotus‐type porous metals and alloys are described together with internal friction, elasticity, thermal conductivity and sound absorption characteristics. All the physical properties exhibit significant anisotropy. Lotus‐type porous iron fabricated using a pressurized nitrogen gas instead of hydrogen exhibits superior strength.     

不同粉末粒度的粉末轧制多孔钛板的孔隙性能研究

为满足湿法冶金、氯碱、水处理、制药等行业对多孔钛板过滤元件的需求,以粉末轧制法制备多孔钛板为出发点,开展了满足轧制工艺要求的多孔钛板粉末轧制、烧结、性能测试等研究。通过对不同性能的钛粉进行粉末轧制、真空烧结,制得了宽度为420 mm、厚度不同、组织均匀的多孔钛板,研究了不同粉末性能对其孔隙度、最大孔径和透气度的影响。结果表明:随着粉末粒度的减小,多孔钛板的密度有所增大,孔隙度、最大孔径和透气度逐渐减小。其中,多孔钛板最大孔径和透气度的变化规律与模压多孔材料的相同。在追求孔隙度最大化时,以最小的轧制压力轧制成型多孔钛板,粉末粒度越大,其厚度越大。当粉末粒度相同时,多孔钛板厚度越大,其内部孔道路径越长,孔结构越复杂,气体在透过多孔结构通道时所消耗的能量也越多,透气度则越低。     

连续梯度不锈钢多孔材料的制备及性能

利用离心沉积工艺制备连续梯度不锈钢多孔试样时,没有使用基体,而是直接在模具中成形,然后脱模、烧结.试验对制备出的连续梯度不锈钢多孔材料的微观形貌、透气度及最大孔径等进行了分析,结果表明,选择合理的烧结制度可以有效避免试样在烧结过程中因各梯度层收缩率不同而引起的变形、开裂问题;国标规定的厚度范围内,最大孔径＜60μm时,连续梯度多孔不锈钢试样的透气度要高于相同最大孔径条件下均匀多孔材料的透气度;另外,在保持相对较高透气度的前提下,连续梯度多孔材料有较大的试样厚度选择空间,此试验结果为连续梯度多孔材料在某些应用领域取代均匀多孔材料提供了试验依据.     

Processing and degradation behavior of porous magnesium scaffold for biomedical applications

Porous magnesium has the potential to be used as degradable bone scaffolds. In this study, porous magnesium scaffolds were fabricated through powder metallurgy route utilizing spherical naphthalene particle as porogen. Porogen was removed at 120?°C for 24?h followed by sintering at 550?°C for 2?h in argon atmosphere. Micro-computed tomography (micro CT) results indicated that scaffolds have interconnected porous structure with an equivalent pore diameter of nearly 60?µm. Compressive strength of the scaffolds was found in the range of 24?±?4.54?MPa to 184?±?9.9?MPa and decreased with increasing porogen content. In vitro degradation study in phosphate buffered saline (PBS) showed that scaffold degradation behavior was governed by its porosity content. Our results indicate that modulating the porogen content we can tailor the mechanical and degradation behavior of the Mg scaffolds to the application need.     

Structural characterization and strengthening mechanism of forsterite nanostructured scaffolds synthesized by multistep sintering method

In this study, highly porous forsterite scaffolds with interconnected porosities were synthesized using multi-step sintering (MSS) method. The starting powder was nanosized forsterite, which was synthesized from talc and magnesium carbonate powders. The phase composition, average particle size and morphology of the produced forsterite powder were characterized by X-ray diffraction technique (XRD) and transition electron microscopy (TEM). Forsterite scaffolds were produced by foamy method using polymeric sponges. MSS process including three steps was used to efficiently sinter the forsterite nanopowders without destroying the initial porous structure of polymeric sponges. The results showed that MSS technique is an efficient and appropriate procedure to produce highly porous forsterite scaffolds with pore size in the range of 100–300?μm. The compressive strength, compressive modulus and porosity of C12 specimen (sintered at 1650?°C for 1?h with subsequent annealing at 1000?°C for 1000?min) was 1.88?MPa, 29.2?MPa, and 72.4%, respectively, which is very close to that of cancellous bone. The approach studied in this research can be developed for other nanostructure ceramics to produce highly porous scaffolds with interconnected porosities for load bearing applications.