Abstract: The successful fabrication of alloy foam (or porous alloy) is very rare, despite their potentially better properties and wider applicability than pure metallic foams. The processing of three-dimensional copper-nickel alloy foams is achieved through a strategic solid-solution alloying method based on oxide powder reduction or sintering processes, or both. Solid-solution alloy foams with five different compositions are successfully created, resulting in open-pore structures with varied porosity. The corrosion resistance of the synthesized copper-nickel alloy foams is superior to those of the pure copper and nickel foams.

Abstract: Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area.

Abstract: A sodium-chloride-space-holder process with two-step heat treatment is used to create an open-porous metal foam (e.g., titanium foam) with a high porosity of about 70 to 90 percent for use in load-bearing applications. A mechanically reliable titanium foam is manufactured using a space-holder method containing two-step heat treatment where a sodium chloride powder is first sieved for desired pore size range, mixed with titanium powder, and compacted under pressure at high temperature. An additional heat treatment is applied to further strengthen the chemical bonding between the titanium particles after the removal of sodium chloride in water to create pores. This process uses a pneumatic pressing machine in combination with a furnace under an argon gas to simultaneously apply both the pressure and temperature. The resulting titanium foam is chemically well bonded and has enhanced durability for proper used in structural applications.

Abstract: A three-dimensional (3D) printing device presented in this invention has a novel printing head design that can be used with a cost-effective 3D printing ink based on cost-competitive camphene solvent utilizing its burning-free, room-temperature solidifying and sublimating properties for 3D printing purposes. The unique combination of the new printing head with pressured air control and the invented ink allows for a mass-production of complex metallic components and parts with a variety of compositions for use in advanced manufacturing in a highly cost-effective way.

Abstract: A capacitor and supercapacitor design are based on metal-foam electrodes. An electrolytic capacitor has a metal foam dielectric (e.g., aluminum oxide, titanium oxide, iron oxide, or others). An electric double-layer supercapacitor has an electrode with metal foam (e.g., copper, nickel, titanium, iron, steel alloy, or aluminum) filled with activated carbon, or graphene, or metal foam with activated carbon foam, or any combination of these to enhance the electrical conductivity and thus the power and capacity of the cell. A pseudocapacitor device has an electrode with metal foam (e.g., iron, cobalt, nickel, copper, titanium, aluminum, magnesium, tin, manganese, and stainless steel, and their alloy foams) coated with an oxide- or hydroxide-based material containing highly active zones. The pseudocapacitor metal-foam electrode can also be filled with activated carbon in the form of a slurry to further enhance its capacity.

Abstract: A facile method is based on a pack-cementation process using large-area copper foil instead of copper powder. By controlling a pack-cementation time and an amount of alloying element (e.g., aluminum), a hierarchical microporous or nanoporous copper can be created. When coated with tin active material, the hierarchical microporous or nanoporous copper can be used as an advanced lithium-ion battery anode. A coin-cell test exhibited a four-fold higher areal capacity (e.g., 7.4 milliamp-hours per square centimeter without any performance degradation up to 20 cycles) as compared to a traditional graphite anode.

Abstract: The successful fabrication of alloy foam (or porous alloy) is very rare, despite their potentially better properties and wider applicability than pure metallic foams. The processing of three-dimensional copper-nickel alloy foams is achieved through a strategic solid-solution alloying method based on oxide powder reduction or sintering processes, or both. Solid-solution alloy foams with five different compositions are successfully created, resulting in open-pore structures with varied porosity. The corrosion resistance of the synthesized copper-nickel alloy foams is superior to those of the pure copper and nickel foams.

Abstract: Anode and cathode electrodes of a rechargeable lithium-ion battery are manufactured using metal foam. This lithium-ion battery with the metal-foam electrodes can have pores coated or filled, or both, with high-capacity active materials for greater energy density, better safety, improved power, and longer cycle life. Aluminum (or nickel) and copper metal-foam electrodes are manufactured using space-holder and freeze-casting methods. An anode can be filled with a graphite or silicon slurry, or a combination. A cathode can be filled with a lithium cobalt oxide (or other higher-capacity active materials) slurry. The relatively thick metal-foam electrodes are attached to the cell, separated by a separator, and wetted by an electrolyte, forming a high-capacity secondary battery. The battery will have higher density, improved power, and good cycle life.

Abstract: Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area.