本論文探討以壓鑄法製備多孔鋁的製作程序，並以消失模鑄漿法與陶瓷球壓鑄成型法為主。消失模鑄漿法中，利用泡綿浸泡於有機溶劑的膨潤現象，增加泡綿骨架結構，進而控制多孔金屬鋁材的骨架粗細，並利用不同規格的泡棉，我們可以製備骨架厚度最細為0.117mm或最粗達0.458mm的多孔金屬鋁，孔隙度值在90∼95% 之間。
而陶瓷球鑄漿製程中，我們使用一特殊的組成配方（氧化鋁粉：皂土：HPMC：水：PVA重量比為100：1：2：48.3：2.4），使陶瓷球具備鑄鋁過程中足夠的強度，並且可以在壓鑄完成後，用高壓水柱除去多孔鋁材內部的陶瓷球，以製備多孔金屬鋁。最重要的是陶瓷球在室溫下具備可塑性，可以利用壓縮的方式，改變陶瓷球堆積體的緊密程度，進而控制成品的孔隙度。另外也可以藉由規則堆積的方法，改善隨意堆積造成的不均勻性，進而改善成品結構的均勻性。本法所得到的多孔鋁成品，其孔隙度約在80∼89% 之間。

The preparation of porous aluminum by die casting was investigated in this work, including both the 〝lost foam 〞method and the〝ceramic ball preform 〞method. In the lost foam die casting method, we utilized the swelling phenomenon caused by soaking the polymer foam in a proper organic solution to increase the ligament thickness and its porosity. As a result, the ligament thickness and porosity of finished products can be easily tailored. Using different polymer foams from various suppliers, we can make porous aluminums whose ligament thickness is in the range of 0.117∼0.458mm and porosity about 90∼95%.
In the ceramic ball preform method, we found a special formula（weight ratio of Al2O3：bentonite：HPMC：water：PVA is 100：1：2：48.3：2.4） for making ceramic balls with sufficient strength to survive the casting procedures. These ceramic balls of several mm in size, can be easily removed from the finished products by high pressure water after casting. One of the ingenuity of this procedure lies in the fact that these ceramic balls are soft and deformable at room temperature. For this reason, we can apply pressure to increase the compactness of the packed bed made of these ceramic balls. As a result, the porosity the finished products can be substantially increased. On the other hand, the uniformity of the product can be improved if regular packing technique was employed rather than the random packing method. On the average, the porosity of the product is in the range of 80∼89%.

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