• Korean Journal of Materials Research
• /
• v.12 no.1
• /
• pp.58-67
• /
• 2002

In this study copper chloride(CuCl$_2$) solution was used as raw material to produce the fine copper oxide powder which has less than 1 $\mu\textrm{m}$ average particle size and has uniform particle size distribution by spray pyrolysis process. In the present study, the effects of reaction temperature, the injection speed of solution and air, the nozzle tip size and the concentration of raw material solution on the properties of produced powder were studied. The structure of the powder became much more compact with increasing the reaction temperature regardless of copper concentration of the raw material solution. The particle size of the powder increased accordingly with increasing the reaction temperature in case of 30 g/$\ell$ copper concentration of the solution. The particle size of the powder increased accordingly, and the surface structure of the powder became more porous with increasing the copper concentration of the raw material solution. When copper concentration in raw material solution was more than 100 g/$\ell$, all produced powder was CuCl regardless of reaction temperatures. When copper concentration in solution was below 30 g/$\ell$ and reaction temperature was higher than 90$0^{\circ}C$, CuO was the main phase. The surface of the powder tended to become porous with increasing the injection speed of solution. Particle size was increased and the surface of the powder showed severely disrupted state with increasing the nozzle tip size. The particle size was decreased and the particle size distribution was more uniform with increasing the air pressure through the nozzle.

• Archives of Metallurgy and Materials
• /
• v.67 no.4
• /
• pp.1531-1534
• /
• 2022

In this study, a SUS316L membrane having double layered pore structures was fabricated, and the pore characteristics were analyzed after coating with a spherical powder and a flake-shaped powder on a disk-shaped SUS316L support using a wet powder spraying process. The thickness of the coated layer was checked using an optical microscope, and air permeability was measured using a capillary flow porometer. When the coating amount was similar, the fine porous layer prepared using flake powder was thicker and showed higher porosity. In the case of a similar thickness, the case of using flake powder was half of the amount of spherical powder used. Therefore, it was confirmed that it is possible to manufacture a metal membrane having a high filter efficiency even with a small coating amount when using the flake powder.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
• /
• v.23 no.10
• /
• pp.814-819
• /
• 2010

Porous carbon electrodes with wooden materials are manufactured by molding carbonized wood powder. Electrical properties of the interface for electrolyte and porous carbon electrode are investigated from viewpoint of NaCl electrolyte concentration, capacitance and complex impedance. Density of porous carbon materials is 0.47~0.61 g/$cm^3$. NaCl electrolytic absorptance of the porous carbon materials is 5~30%. As the electrolyte concentration increased, capacitance is increased and electric resistance is decrease with electric double layer effect of the interface. The electric current of the porous carbon electrode compared in the copper and the high density carbon electrode was improved on a large scale, due to a increase in surface area. The circuit current increased as the distance between of the porous carbon electrode and the zinc electrode decreased, due to increase in electric field. Experimental results indicated that the current properties of galvanic cell could be improved by using porous carbon electrode.

• Korean Journal of Materials Research
• /
• v.16 no.3
• /
• pp.188-192
• /
• 2006

The microstructures and mechanical properties of continuously porous $SiC-Si_3N_4$composites fabricated by multi-pass extrusion were investigated at different Si levels added. Si-powder with different weight percentages (0%, 5%, 10%, 15%, 20%) was added to the SiC powder to make the raw mixture powders, with $6wt%Y_2O_3-2wt%Al_2O_3$ as sintering additives, carbon ($10-15{\mu}m$) as a pore-forming agent, ethylene vinyl acetate as a binder and stearic acid ($CH_3(CH_2)_{16}COOH$) as a lubricant. In the continuously porous $SiC-Si_3N_4$ composites, $Si_3N_4$ whiskers like the hairs of nostrils were frequently observed on the wall of the pores. In this study, the morphology of the $Si_3N_4$ whiskers was investigated with the silicon addition content. In the composites containing of 10 wt% Si, a large number of $Si_3N_4$ whiskers was found at the continuous pore regions. In the sample to which 15 wt% Si powder was added, maximum values of about 101 MPa bending strength and 57.5% relative density were obtained.

• Journal of Powder Materials
• /
• v.23 no.1
• /
• pp.49-53
• /
• 2016

The present study demonstrates the effect of freezing conditions on the pore structure of porous Cu-10 wt.% Sn prepared by freeze drying of $CuO-SnO_2$/camphene slurry. Mixtures of CuO and $SnO_2$ powders are prepared by ball milling for 10 h. Camphene slurries with 10 vol.% of $CuO-SnO_2$ are unidirectionally frozen in a mold maintained at a temperature of $-30^{\circ}C$ for 1 and 24 h, respectively. Pores are generated by the sublimation of camphene at room temperature. After hydrogen reduction and sintering at $650^{\circ}C$ for 2 h, the green body of the $CuO-SnO_2$ is completely converted into porous Cu-Sn alloy. Microstructural observation reveals that the sintered samples have large pores which are aligned parallel to the camphene growth direction. The size of the large pores increases from 150 to $300{\mu}m$ with an increase in the holding time. Also, the internal walls of the large pores contain relatively small pores whose size increases with the holding time. The change in pore structure is explained by the growth behavior of the camphene crystals and rearrangement of the solid particles during the freezing process.

• Journal of Powder Materials
• /
• v.19 no.6
• /
• pp.446-450
• /
• 2012

In order to fabricate the porous Mo with controlled pore characteristics, unique processing by using $MoO_3$ powder as the source and camphene as the sublimable material is introduced. Camphene-based 15 vol% $MoO_3$ slurries, prepared by milling at $50^{\circ}C$ with a small amount of dispersant, were frozen at $-25^{\circ}C$. Pores were generated subsequently by sublimation of the camphene during drying in air for 48 h. The green body was hydrogen-reduced at $750^{\circ}C$, and sintered at $1000-1100^{\circ}C$ for 1 h. After heat treatment in hydrogen atmosphere, $MoO_3$ powders were completely converted to metallic W without any reaction phases. The sintered samples showed large pores with the size of about $150{\mu}m$ which were aligned parallel to the camphene growth direction. Also, the internal wall of large pores and near bottom part of specimen had relatively small pores due to the difference in the camphene growth rate during freezing process. The size of small pores was decreased with increase in sintering temperature, while that of large pores was unchanged. The results are strongly suggested that the porous metal with required pore characteristics can be successfully fabricated by freeze-drying process using metal oxide powders.

• Korean Journal of Materials Research
• /
• v.23 no.12
• /
• pp.722-726
• /
• 2013

Freeze drying of a porous Cu-Sn alloy with unidirectionally aligned pore channels was accomplished by using a composite powder of CuO-$SnO_2$ and camphene. Camphene slurries with CuO-$SnO_2$ content of 3, 5 and 10 vol% were prepared by mixing with a small amount of dispersant at $50^{\circ}C$. Freezing of a slurry was done at $-25^{\circ}C$ while the growth direction of the camphene was unidirectionally controlled. Pores were generated subsequently by sublimation of the camphene during drying in air for 48 h. The green bodies were hydrogen-reduced at $650^{\circ}C$ and then were sintered at $650^{\circ}C$ and $750^{\circ}C$ for 1 h. XRD analysis revealed that the CuO-$SnO_2$ powder was completely converted to Cu-Sn alloy without any reaction phases. The sintered samples showed large pores with an average size of above $100{\mu}m$ which were aligned parallel to the camphene growth direction. Also, the internal walls of the large pores had relatively small pores. The size of the large pores decreased with increasing CuO-$SnO_2$ content due to the change of the degree of powder rearrangement in the slurry. The size of the small pores decreased with increase of the sintering temperature from $650^{\circ}C$ to $750^{\circ}C$, while that of the large pores was unchanged. These results suggest that a porous alloy body with aligned large pores can be fabricated by a freeze-drying and hydrogen reduction process using oxide powders.

• Journal of Powder Materials
• /
• v.25 no.1
• /
• pp.25-29
• /
• 2018

Porous Cu with a dispersion of nanoscale $Al_2O_3$ particles is fabricated by freeze-drying $CuO-Al_2O_3$/camphene slurry and sintering. Camphene slurries with $CuO-Al_2O_3$ contents of 5 and 10 vol% are unidirectionally frozen at $-30^{\circ}C$, and pores are generated in the frozen specimens by camphene sublimation during air drying. The green bodies are sintered for 1 h at $700^{\circ}C$ and $800^{\circ}C$ in $H_2$ atmosphere. The sintered samples show large pores of $100{\mu}m$ in average size aligned parallel to the camphene growth direction. The internal walls of the large pores feature relatively small pores of ${\sim}10{\mu}m$ in size. The size of the large pores decreases with increasing $CuO-Al_2O_3$ content by the changing degree of powder rearrangement in the slurry. The size of the small pores decreases with increasing sintering temperature. Microstructural analysis reveals that 100-nm $Al_2O_3$ particles are homogeneously dispersed in the Cu matrix. These results suggest that a porous composite body with aligned large pores could be fabricated by a freeze-drying and $H_2$ reducing process.

• Korean Journal of Materials Research
• /
• v.31 no.6
• /
• pp.313-319
• /
• 2021

Understanding of effects of changes in the particle size of the matrix material on the mullite whisker growth during the production of porous mullite is crucial for better design of new porous ceramics materials in different applications. Commercially, raw materials such as Al₂O₃/SiO₂ and Al(OH)₃/SiO₂ are used as starting materials, while AlF₃ is added to fabricate porous mullite through reaction sintering process. When Al₂O₃ is used as a starting material, a porous microstructure can be identified, but a more developed needle shaped microstructure is identified in the specimen using Al(OH)₃, which has excellent reactivity. The specimen using Al₂O₃/SiO₂ composite powder does not undergo mulliteization even at 1,400 ℃, but the specimen using the Al(OH)₃/SiO₂ composite powder had already formed complete mullite whiskers from the particle size specimen milled for 3 h at 1,100 ℃. As a result, the change in sintering temperature does not significantly affect formation of microstructures. As the particle size of the matrix materials, Al₂O₃ and Al(OH)₃, decreases, the porosity tends to decrease. In the case of the Al(OH)₃/SiO₂ composite powder, the highest porosity obtained is 75 % when the particle size passes through a milling time of 3 h. The smaller the particle size of Al(OH)₃ is and the more the long/short ratio of the mullite whisker phase decreases, the higher the density becomes.

• Korean Journal of Materials Research
• /
• v.34 no.1
• /
• pp.12-20
• /
• 2024

This study successfully prepared high-porosity aluminosilicate fibrous porous ceramics through vacuum suction filtration using aluminosilicate fiber as the primary raw material and glass powder as binder, with the appropriate incorporation of glass fiber. The effects of the composition of raw materials and sintering process on the structure and properties of the material were studied. The results show that when the content of glass powder reached 20 wt% and the samples were sintered at the temperature of 1,000 ℃, strong bonds were formed between the binder phase and fibers, resulting in a compressive strength of 0.63 MPa. When the sintering temperatures were increased from 1,000 ℃ to 1,200, the open porosity of the samples decreased from 89.08 % to 82.38 %, while the linear shrinkage increased from 1.13 % to 10.17 %. Meanwhile, during the sintering process, a large amount of cristobalite and mullite were precipitated from the aluminosilicate fibers, which reduced the performance of the aluminosilicate fibers and hindered the comprehensive improvement in sample performance. Based on these conditions, after adding 30 wt% glass fiber and being sintered at 1,000 ℃, the sample exhibited higher compressive strength (1.34 MPa), higher open porosity (89.13 %), and lower linear shrinkage (5.26 %). The aluminosilicate fibrous porous ceramic samples exhibited excellent permeability performance due to their high porosity and interconnected three-dimensional pore structures. When the samples were filtered at a flow rate of 150 mL/min, the measured pressure drop and permeability were 0.56 KPa and 0.77 × 10^-6 m² respectively.