Method for Producing Metal or Ceramic Components and Components

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This invention describes a method for manufacturing metal or ceramic components that have regions of different porosities within a single part. The process uses powder or a pre-sintered component, and during a pressure-assisted compaction and sintering step, at least one specially shaped ram (stempel) is used. The contact surface of the ram has both an outer flat region and at least one inner region with a concave recess, so that during compacting and sintering, areas of the component experience different pressures and thus different levels of porosity. The resulting part has a dense outer area and a more porous inner area, which is useful as a substrate for membranes in gas separation, fuel cells, or electrolysis cells.

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• Production of substrates for gas separation membranes, such as hydrogen or oxygen separation devices.
• Manufacture of supporting structures for fuel cells (e.g., solid oxide fuel cells) or electrolysis cells.
• Components requiring integrated areas with different porosities, such as filter elements or catalyst supports.
• Membrane reactors where robust, dense sealing edges and highly porous membrane support regions are desired.
• Any application within powder metallurgy or ceramics that demands customization of porosity within a single component.

BenefitsContent extracted from patent full text and abstract with AI.

• Can manufacture components with tailored porosity in a single or two-step process, making production more efficient.
• Enables precise definition of dense and porous regions, improving the usability of substrates for membrane applications.
• Reduces the risk of defects and weaknesses associated with post-sintering joining or welding methods (like cracks or reduced corrosion resistance).
• Improves the reliability and gas-tightness of membrane installations in reactors or cells.
• Eliminates or reduces problem zones like heat-affected areas and geometric irregularities, leading to stronger and more robust parts.
• Scalable from lab to industrial scale, providing flexibility and applicability across industry sectors.

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Patent Abstract

The invention relates to a method for producing a metal or ceramic component, wherein powder or a pre-sintered component is used, and the component is produced via a pressure-supported compacting and sintering step by means of at least one ram. According to the invention, a ram is used, the contact surface of which has an outer flat region and at least one inner region with a concave recess, whereby a component with regions of different porosities is produced during the compacting and sintering step at a maximum temperature (Τ1) and a predetermined force. With said method, it is possible to produce a metal or ceramic component in two method steps or preferably in only one method step, in such a way that the component has an outer flat region and at least one inner region with a convex elevation, and wherein the porosity of the outer flat region is significantly lower than the porosity of the inner region. A component of this type can be used preferably as a substrate/carrier for a diaphragm in a gas separation device or in a fuel or electrolysis cell.