Porous Fe-Cu-C alloy was sintered by Pulsed Current Activated Sintering(PCAS) method within 10 min from horizontal ball mill mixture. The relative density of Fe-20wt.%Cu-0.8wt.%C alloy fabricated by PCAS method was 91%. The average hardness of the Fe-20wt.%Cu-0.8wt.%C alloy was HRB 92. The phase analysis, microstructure and composition information of the sintered alloy were investigated by using XRD, FESEM, EDAX.

The effect of sublimable vehicles on the pore structure of Cu fabricated by freeze drying is investigated. The 5 vol% CuO-dispersed slurries with camphene and various camphor-naphthalene compositions are frozen in a Teflon mold at -25oC, followed by sublimation at room temperature. After hydrogen reduction at 300oC and sintering at 600 °C, the green bodies of CuO are completely converted to Cu with various pore structures. The sintered samples prepared using CuO/camphene slurries show large pores that are aligned parallel to the sublimable vehicle growth direction. In addition, a dense microstructure is observed in the bottom section of the specimen where the solidification heat was released, owing to the difference in the solidification behavior of the camphene crystals. The porous Cu shows different pore structures, such as dendritic, rod-like, and plate shaped, depending on the composition of the camphornaphthalene system. The change in pore structure is explained by the crystal growth behavior of primary camphor and eutectic and primary naphthalene. Keywords: Porous Cu, Pore structure

Porous Cu-14 wt% Co with aligned pores is produced by a freeze drying and sintering process. Unidirectional freezing of camphene slurry with CuO-Co3O4 powders is conducted, and pores in the frozen specimens are generated by sublimation of the camphene crystals. The dried bodies are hydrogen-reduced at 500oC and sintered at 800oC for 1 h. The reduction behavior of the CuO-Co3O4 powder mixture is analyzed using a temperature-programmed reduction method in an Ar-10% H2 atmosphere. The sintered bodies show large and aligned parallel pores in the camphene growth direction. In addition, small pores are distributed around the internal walls of the large pores. The size and fraction of the pores decrease as the amount of solid powder added to the slurry increases. The change in pore characteristics according to the amount of the mixed powder is interpreted to be due to the rearrangement and accumulation behavior of the solid particles in the freezing process of the slurry.

본 연구에서는 구리 이온(Cu2+ ion) 제거를 위한 산화철(Fe3O4)/다공성 탄소 복합체를 합성하였으며, 이를 바탕으로 구리 이온 제거에 대한 특성 평가를 실시하였다. SEM, XRD 분석을 진행하여 수열합성(hydrothermal) 반응을 이용한 산화철/다공성 탄소 복합체의 형태와 구조를 확인하였다. BET 분석을 통해 비표면적과 기공 크기를 확인하였으며, UV-vis 장비를 통해 성능 평가를 실시하여 자성이 있는 Fe3O4와 다공성 탄소와의 시너지효과를 통해 액체 상태에서 존재하는 구리 이온을 제거할 수 있는 가능성을 제시하였다.

In this study, porous Mo-5 wt% Cu with unidirectionally aligned pores is prepared by freeze drying of camphene slurry with MoO3-CuO powders. Unidirectional freezing of camphene slurry with dispersion stability is conducted at -25℃, and pores in the frozen specimens are generated by sublimation of the camphene crystals. The green bodies are hydrogen-reduced at 750℃ and sintered at 1000℃ for 1 h. X-ray diffraction analysis reveals that MoO3- CuO composite powders are completely converted to a Mo-and-Cu phase without any reaction phases by hydrogen reduction. The sintered bodies with the Mo-Cu phase show large and aligned parallel pores to the camphene growth direction as well as small pores in the internal walls of large pores. The pore size and porosity decrease with increasing composite powder content from 5 to 10 vol%. The change of pore characteristics is explained by the degree of powder rearrangement in slurry and the accumulation behavior of powders in the interdendritic spaces of solidified camphene.

Porous Cu with a dispersion of nanoscale Al2O3 particles is fabricated by freeze-drying CuO-Al2O3/camphene slurry and sintering. Camphene slurries with CuO-Al2O3 contents of 5 and 10 vol% are unidirectionally frozen at -30oC, and pores are generated in the frozen specimens by camphene sublimation during air drying. The green bodies are sintered for 1 h at 700oC and 800oC in H2 atmosphere. The sintered samples show large pores of 100 μm in average size aligned parallel to the camphene growth direction. The internal walls of the large pores feature relatively small pores of ~10 μm in size. The size of the large pores decreases with increasing CuO-Al2O3 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 Al2O3 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 H2 reducing process.

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-SnO2/camphene slurry. Mixtures of CuO and SnO2 powders are prepared by ball milling for 10 h. Camphene slurries with 10 vol.% of CuO-SnO2 are unidirectionally frozen in a mold maintained at a temperature of -30oC for 1 and 24 h, respectively. Pores are generated by the sublimation of camphene at room temperature. After hydrogen reduction and sintering at 650oC for 2 h, the green body of the CuO-SnO2 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 μm 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.

The effect of sublimable vehicle composition in the camphor-naphthalene system on the pore structure ofporous Cu-Ni alloy is investigated. The CuO-NiO mixed slurries with hypoeutectic, eutectic and hypereutectic compo-sitions are frozen into a mold at -25oC. Pores are generated by sublimation of the vehicles at room temperature. Afterhydrogen reduction at 300oC and sintering at 850oC for 1 h, the green body of CuO-NiO is completely converted toporous Cu-Ni alloy with various pore structures. The sintered samples show large pores which are aligned parallel to thesublimable vehicle growth direction. The pore size and porosity decrease with increase in powder content due to thedegree of powder rearrangement in slurry. In the hypoeutectic composition slurry, small pores with dendritic morphologyare observed in the sintered Cu-Ni, whereas the specimen of hypereutectic composition shows pore structure of plateshape. The change of pore structure is explained by growth behavior of primary camphor and naphthalene crystals dur-ing solidification of camphor-naphthalene alloys.

This study reports a simple way of fabricating the porous Cu with unidirectional pore channels by freezedrying camphene slurry with Cu oxide coated Cu powders. The coated powders were prepared by calcination of ball-milled powder mixture of Cu and Cu-nitrate. Improved dispersion stability of camphene slurry could be achieved usingthe Cu oxide coated Cu powders instead of pure Cu powders. Pores in the frozen specimen at -25oC were generated bysublimation of the camphene during drying in air, and the green bodies were sintered at 750oC for 1 h in H2 atmo-sphere. XRD analysis revealed that the coated layer of Cu oxide was completely converted to Cu phase without anyreaction phases by hydrogen heat treatment. The porous Cu specimen prepared from pure Cu powders showed partlylarge pores with unidirectional pore channels, but most of pores were randomly distributed. In contrast, large andaligned parallel pores to the camphene growth direction were clearly observed in the sample using Cu oxide coated Cupowders. Pore formation behavior depending on the initial powders was discussed based on the degree of powder rear-rangement and dispersion stability in slurry.

Cu-Ni alloys with unidirectionally aligned pores were prepared by freeze-drying process of CuO-NiO/cam-phene slurry. Camphene slurries with dispersion stability by the addition of oligomeric polyester were frozen at -25˚C,and pores in the frozen specimens were generated by sublimation of the camphene during drying in air. The green bod-ies were hydrogen-reduced at 300˚C and sintered at 850˚C for 1h. X-ray diffraction analysis revealed that CuO-NiOcomposite powders were completely converted to Cu-Ni alloy without any reaction phases by hydrogen reduction. Thesintered samples showed large and aligned parallel pores to the camphene growth direction, and small pores in the inter-nal wall of large pores. The pore size and porosity decreased with increase in CuO-NiO content from 5 to 10 vol%.The change of pore characteristics was explained by the degree of powder rearrangement in slurry and the accumulationbehavior of powders in the interdendritic spaces of solidified camphene.

In order to fabricate the porous Al₂O₃ with dispersion of nano-sized Cu particles, freeze-drying of cam-phene/Al₂O₃ slurry and solution chemistry process using Cu-nitrate are introduced. Camphene slurries with 10vol% Al₂O₃ was frozen at -25˚C. Pores were generated by sublimation of the camphene during drying in air. The sinteredsamples at 1400 and 1500oC showed the same size of large pores which were aligned parallel to the sublimable vehiclesgrowth direction. However, the size of fine pores in the internal walls of large pores decreased with increase in sinteringtemperature. It was shown that Cu particles with the size of 100 nm were homogeneously dispersed on the surfaces ofthe large pores. Antibacterial test using fungus revealed that the porous Al₂O₃/1vol% Cu composite showed antifungalproperty due to the dispersion of Cu particles. The results are suggested that the porous composites with required porecharacteristics and functional property can be fabricated by freeze-drying process and addition of functional nano par-ticles by chemical method.

Freeze drying of a porous Cu-Sn alloy with unidirectionally aligned pore channels was accomplished by using a composite powder of CuO-SnO2 and camphene. Camphene slurries with CuO-SnO2 content of 3, 5 and 10 vol% were prepared by mixing with a small amount of dispersant at 50˚C. Freezing of a slurry was done at -25˚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˚C and then were sintered at 650˚C and 750˚C for 1 h. XRD analysis revealed that the CuO-SnO2 powder was completely converted to Cu-Sn alloy without any reaction phases. The sintered samples showed large pores with an average size of above 100μm 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-SnO2 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˚C to 750˚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.

Al-based alloys have recently attracted considerable interest as structural materials and light weight materials due to their excellent physical and mechanical properties. For the investigation of the potential of Al-based alloys, a surface porous Al88Cu6Si6 eutectic alloy has been fabricated through a chemical leaching process. The formation and microstructure of the surface porous Al88Cu6Si6 eutectic alloy have been investigated using X-ray diffraction and scanning electron microscopy. The Al88Cu6Si6 eutectic alloy is composed of an α-Al dendrite phase and a single eutectic phase of Al2Cu and α-Al. We intended to remove only the α-Al phase and then the Al2Cu phase would form a porous structure on the surface with open pores. Both acidic and alkaline aqueous chemical solutions were used with various concentrations to modify the influence on the microstructure and the overall chemical reaction was carried out for 24 hr. A homogeneous open porous structure on the surface was revealed via selective chemical leaching with a H2SO4 solution. Only the α-Al phase was successfully leached while the morphology of the Al2Cu phase was maintained. The pore size was in a range of 1~5μm and the dealloying depth was nearly 3μm. However, under an alkaline NaOH, aqueous solution, an inhomogeneous porous structure on the surface was formed with a 5 wt% NaOH solution and the morphology of the Al2Cu phase was not preserved. In addition, the sample that was leached by using a 7 wt% NaOH solution crumbled. Al extracted from the Al2Cu phase as α-Al phase was dealloyed, and increasing concentration of NaOH strongly influenced the morphology of the Al2Cu phase and sample statement.

Porous Al2O3 dispersed with nano-sized Cu was fabricated by freeze-drying process and solution chemistry method using Cu-nitrate. To prepare porous Al2O3, camphene was used as the sublimable vehicle. Camphene slurries with Al2O3 content of 10 vol% were prepared by milling at 50˚C with a small amount of oligomeric polyester dispersant. Freezing of the slurry was done in a Teflon cylinder attached to a copper bottom plate cooled to -25˚C while unidirectionally controlling the growth direction of the camphene. Pores were subsequently generated by sublimation of the camphene during drying in air for 48 h. The green body was sintered in a furnace at 1400˚C for 1 h. Cu particles were dispersed in porous Al2O3 by calcination and hydrogen reduction of Cu-nitrate. The sintered samples showed large pores with sizes of about 150μm; these pores were aligned parallel to the camphene growth direction. Also, the internal walls of the large pores had relatively small pores due to the traces of camphene left between the concentrated Al2O3 particles on the internal wall. EDS analysis revealed that the Cu particles were mainly dispersed on the surfaces of the large pores. These results strongly suggest that porous Al2O3 with Cu dispersion can be successfully fabricated by freeze-drying and solution chemistry routes.

In this study, gradient porous Al-Cu sintered body was fabricated by powder metallurgy processing. Al-Cu powder mixtures were prepared by low energy ball milling with various milling time. After ball milling for 3h, the shape of powder mixtures changed to spherical type with size of 100~500 . Subsequently, Al-Cu powder mixtures were classified (under 150, 150~300 and over 300 ) and compacted (20, 50 and 100 MPa). Then, they were sintered at for various holding time (10, 30, 60 and 120 min) in atmosphere. The sintered bodies had 32~45% of porosity. As a result, the optimum holding time was determined to be 60 min at and sintered bodies with various porosity were obtained by controlling the compacting pressure.

In order to fabricate the porous metal with controlled pore characteristics, unique processing by using metal oxide powder as the source and camphene as the sublimable material is introduced. CuO powder was selected as the source for the formation of Cu metal via hydrogen reduction. Camphene-based CuO slurry, prepared by milling at with a small amount of dispersant, was frozen at . Pores were generated subsequently by sublimation of the camphene. The green body was hydrogen-reduced at for 30 min, and sintered at for 1 h. Microstructural analysis revealed that the sintered Cu showed aligned large pore channels parallel to the camphene growth direction, and fine pores are formed around the large pore. Also, it showed that the pore size was controllable by the slurry concentration.

Al-Cu alloy nano powders have been produced by the electrical explosion of Cu-plated Al wire. The porous nano particles were prepared by leaching for Al-Cu alloy nano powders in 40wt% NaOH aqueous solution. The surface area of leached powder for 5 hours was 4 times larger than that of original alloy nano powder. It is demonstrated that porous nano particles could be obtained by selective leaching of alloy nano powder. It is expected that porous Cu nano powders can be applied for catalyst of SRM (steam reforming methanol).