Papers by Keyword: Continuous Zone Melting Technique

Abstract: Lotus-type porous metals with low thermal conductivity are fabricated by continuous zone melting technique, which possess directional elongated pores. The porous metals have been able to be fabricated through the conventional casting method by utilizing the solubility gap between solid and liquid in pressurized gas atmosphere. However, there is a shortcoming that the pores are coarsened in the part farther from the chill plate in the ingot. In order to overcome such a shortcoming, we developed the continuous zone melting technique and successfully produced the lotus-type porous metals with even low thermal conductivity such as stainless steel and superalloys. Furthermore, from the viewpoint of mass production with low cost, we invented novel ”continuous casting technique”. The molten metals dissolving gas are solidified continuously by passing through the mold cooled with chiller and thus, lotus-type porous metal plate as long as one meter was produced for short time. Sufficient uniformity of the porosity and pore size was obtained in such long porous ingots. This technique is prospective method for commercial mass production.

Abstract: Lotus-type porous Fe-25wt.%Cr and Fe-23wt.%Cr-2wt.%Mo alloys were fabricated by continuous zone melting technique in pressurized hydrogen gas. After applying a high temperature nitriding treatment, the fabricated Lotus-type porous nickel-free stainless steel absorbed larger amount of nitrogen compared with non-porous alloy of the same composition since the surface area exposed to the gas is larger in the porous samples. In the Lotus-type porous Fe-25wt.%Cr and Fe-23wt.%Cr-2wt.%Mo alloys the nitrogen concentration after the nitriding achieved was approximately 1.2 wt.%. Only austenite peaks were detected in the profile of both Fe-Cr-N alloys after the nitriding treatment. Neither CrN nor Cr2N were identified by XRD in any specimen after the nitriding.