Porous metallic surfaces are used in wide range of applications including energy conversion systems, heat exchangers (for heat and mass transfer) and biomedical implants (for osseointegration) etc. This study proposes a methodology for manufacturing of 3-d gradient porous surfaces that can be utilized for both advanced heat transfer products and solid oxide fuel cell (SOFC) interconnects applications. Annealed spherical copper powders up to 106 micron in diameter were compacted onto thin copper substrates. Manufacturing parameters such as temperature, pressure, and powder size were the variables in the experimentation. In addition, manufactured samples were sintered at different temperatures (600 and 900 °C ) to reveal the effect of sintering temperature on porosity and microhardness. Analyses showed that both manufacturing parameters and sintering temperatures are effective on the porosity and microhardness.
Keywords: Porous surfaces, Micro-manufacturing, Copper powders.