Aluminum-based porous body and method for manufacturing same

Abstract

An aluminum-based porous body having a three-dimensional network structure with sufficient strength and a production method therefor are provided. In the three-dimensional network structure, aluminum powder particles or aluminum alloy powder particles are used, and they are strongly bonded to each other. The porous body is obtained as follows. A resin three-dimensional network structure body is used as a substrate. Then, at least one of aluminum powder and aluminum alloy powder is adhered on a surface of the resin strut of the substrate, and the adhered powder is heated to not less than the melting point thereof so as to eliminate and remove the substrate and to melt the adhered powder. The porous body is made of aluminum or the aluminum alloy and has a strut with a density ratio of not less than 90%, and aluminum oxide is dispersed in an inner part of the strut.

1 . An aluminum-based porous body comprising:
 a strut which is connected three-dimensionally; and   a three-dimensional network structure, which includes communicating holes that are formed by the strut so as to three-dimensionally communicate with each other,   wherein the strut is made of aluminum or aluminum alloy having a density ratio of not less than 90% and contains an aluminum oxide that is dispersed in an inner part of the strut.   
     
     
         2 . The aluminum-based porous body according to  claim 1 , wherein the strut includes pores in the inner part thereof, and the pores have sizes of not greater than 10 μm. 
     
     
         3 . The aluminum-based porous body according to  claim 1 , wherein the aluminum oxide has a size of not greater than 10 μm. 
     
     
         4 . The aluminum-based porous body according to  claim 1 , wherein the strut is hollow. 
     
     
         5 . An aluminum-based porous body comprising:
 a strut, which is connected three-dimensionally; and   communicating holes, which are made to three-dimensionally communicate with each other by the strut,   wherein the strut has a three-dimensional network structure that is made of aluminum or aluminum alloy, and   the aluminum-based porous body shows a stress-strain diagram, in which a stress amount is increased with the increase in a strain amount when a load is applied, and the stress becomes approximately constant due to crushing of the communicating holes and is then increased.   
     
     
         6 . The aluminum-based porous body according to  claim 5 , wherein
 the strut has a density ratio of 90% or more.   
     
     
         7 . The aluminum-based porous body according to  claim 6 , wherein the strut includes pores in an inner part thereof, and the pores have sizes of not greater than 10 μm. 
     
     
         8 . The aluminum-based porous body according to  claim 5 , wherein crushed pieces are generated when the load is applied until the load is increased after the stress is approximately constant in the stress-strain diagram, and the amount of the crushed pieces is not more than 5 mass % of the aluminum-based porous body. 
     
     
         9 . A production method for an aluminum-based porous body, comprising:
 using a resin three-dimensional network structure body, which has a resin strut that is connected three-dimensionally and which includes communicating holes that are formed by the resin strut so as to three-dimensionally communicate with each other, as a substrate;   adhering at least one of aluminum powder and aluminum alloy powder on a surface of the resin strut of the substrate; and   heating the adhered powder to not less than the melting point of the adhered powder in a nonoxidizing atmosphere so as to eliminate and remove the substrate and to melt the adhered powder.   
     
     
         10 . The production method for the aluminum-based porous body according to  claim 9 , wherein the heating is performed at a temperature of from the melting point to the melting point+100° C. 
     
     
         11 . The production method for the aluminum-based porous body according to  claim 9 , wherein the powder of at least one of the aluminum powder and the aluminum alloy powder has an average particle diameter of 1 to 50 μm. 
     
     
         12 . The production method for the aluminum-based porous body according to  claim 9 , wherein the powder of at least one of the aluminum powder and the aluminum alloy powder is adhered on the surface of the resin strut so that the thickness is 100 to 1000 μm. 
     
     
         13 . The production method for the aluminum-based porous body according to  claim 9 , wherein the adhering of at least one of the aluminum powder and the aluminum alloy powder on the surface of the resin strut of the substrate is performed by:
 preparing a dispersion liquid by dispersing at least one of the aluminum powder and the aluminum alloy powder in a dispersion medium and by adjusting the dispersion liquid so that the viscosity is 50 to 1000 Pa·s under a temperature condition of 25° C.;   immersing the substrate in the dispersion liquid; and then   drying the substrate.   
     
     
         14 . An aluminum-based porous body obtained by the production method according to  claim 9 .