OPEN PORE CERAMIC MATRIX FOAMS COATED WITH METAL OR METAL ALLOYS AND METHODS OF MAKING SAME
Open pore foams are coated with metal or metal alloys by electrolytic or electroless plating. The characteristics of the plating bath are adjusted to decrease the surface tension such that the plate bath composition can pass into the pores of the foam, preferably at least two and most preferably more than five pores in depth from the surface of the foam matrix. This can be accomplished by adding a surfactant, solvent or other constituent to reduce the surface tension of the plate bath. In addition, heat and pressure can be used to drive in the plate bath composition into the passage ways of connected open pores in the foam matrix. The net result is to plate the inside surfaces of the pores in the foam matrix, while maintaining the passageways through the foam. Pretreatment of the pore surfaces can be used to promote adhesion of the metal. Particularly advantageous results are achieved when the foam matrix is a ceramic foam.