Fabrication of porous aluminium with directional pores through thermal decomposition method

Lotus-type porous metals were fabricated by unidirectional solidification in pressurized gas atmosphere. The elongated pres are evolved by insoluble gas resulted from the solubility gap between liquid and solid when the melt is solidified. Recently we developed a novel fabrication technique, in which gas compounds are used as a source of dissolving gas instead of the high pressure. In the present work this gas compound method was applied to fabrication of lotus aluminium. Hydrogen decomposed from calcium hydroxide, sodium bicarbonate and titanium hydride evolves cylindrical pores in aluminium. The porosity is about 20%. The pore size decreases and the pore number density increases with increasing amount of calcium hydroxide, which is explained by increase in pore nucleation sites.