High aspect ratio porous microfeatures are becoming more important in the modern industry. However, the fabrication of such features under a mass production environment remains a challenge when robustness, cost effectiveness, and high productivity requirements are required. In this study, the forming of such porous microfeatures using hot compaction was investigated. A hot compaction experimental setup was designed and fabricated that is capable of performing high temperature operation (700°C), quick heatup, and avoiding oxidation. 3D thermal simulation of the experimental setup was conducted to investigate the heat transfer performance and internal temperature distribution, which was then used as a reference for the experiment. Hot compaction experiments were carried out, and the effects of compression force and temperature on the quality in terms of powder consolidation strength and porosity were investigated. In addition, the achievable aspect ratio and taper angle were also discussed.

1.
Liter
,
S. G.
, and
Kaviany
,
M.
, 2001, “
Pool-Boiling CHF Enhancement by Modulated Porous-Layer Coating: Theory and Experiment
,”
Int. J. Heat Mass Transfer
0017-9310,
44
(
22
), pp.
4287
4311
.
2.
Larminie
,
J.
, and
Dicks
,
A.
, 2003,
Fuel Cell Systems Explained
,
2nd ed.
,
Wiley
,
England
.
3.
Bose
,
A.
, 1993, “
Particulate-Based Biomaterials: Processing and Applications
,”
Reviews in Particulate Materials
,
1
, pp.
161
222
.
4.
Chen
,
P.
,
Ni
,
J.
and
Koc
,
M.
, 2008, “
Manufacturing of Porous Coatings With Micro-Scale Features for Improved Boiling Heat Transfer
,”
Proceedings of the International Conference on Manufacturing Science and Engineering, MSEC 2006
.
5.
Kartsounes
,
G. T.
, 1975, “
A Study of the Effect of Surface Treatment on Pool Boiling Heat Transfer in Refrigerant 12
,”
ASHRAE Trans.
0001-2505,
81
(
1
), pp.
320
326
.
6.
Dahl
,
M. M.
, and
Erb
,
L. D.
, 1976, “
Liquid Heat Exchanger Interface and Method
,” U.S. Patent 3,990,862.
7.
German
,
R. M.
, 1996,
Sintering Theory and Practice
,
Wiley
,
New York
.
8.
German
,
R. M.
, 1994,
Powder Metallurgy Science
,
Metal Powder Industries Federation
,
Princeton, NJ
.
9.
Walter
,
A. J.
, and
Trowell
,
A. R.
, 1971, “
The Thermal Conductivity of Porous Copper
,”
J. Mater. Sci.
0022-2461,
6
(
7
), pp.
1044
1046
.
10.
Holman
,
J. P.
, 1997,
Heat Transfer
,
8th ed.
,
McGraw-Hill Companies
,
New York
.
11.
Yuncu
,
H.
, 2006, “
Thermal Contact Conductance of Nominaly Flat Surfaces
,”
Heat Mass Transfer
0947-7411,
43
(
1
), pp.
1
5
.
12.
1970,
Heat Transfer Data Book
,
Fitzroy
,
N. D.
, ed.,
General Electric Company
,
Schenectady, NY
.
13.
Incropera
,
F. P.
, and
Dewitt
,
D. P.
, 1996,
Fundamentals of Heat and Mass Transfer
,
4th ed.
,
Wiley
,
New York
.
You do not currently have access to this content.