Fabrication and Characterization of Highly Porous FeAl‐Based Intermetallics by Thermal Explosion Reaction

Abstract

Porous FeAl-based intermetallics with different nominal compositions ranging from Fe-40 at% Al to Fe-60 at% Al are prepared by a novel process of thermal explosion (TE) mode. The results show that the Al content significantly affects the combustion behavior of the specimens, the ignition temperature of the Fe-Al intermetallics varies from 641 to 633 C and the combustion temperature from 978 to 1179 C. The porous materials exhibit uniform pore structures with porosities and average pore sizes of 52-61% and 20-25 mm, respectively. The TE reaction is the dominant pore formation mechanism regardless of the alloy composition. However, differences in the porosity and average pore size are observed depending on the Al content. The compressive strength of porous Fe-Al intermetallics is in the range of 23-34 MPa, duly applied as filters. Additionally, a surface alumina layer is formed at the early stage and both of the oxidation process and the sulfidation process follows the familiar parabolic rate law in the given atmosphere, exhibiting excellent resistance to oxidation and sulfidation. These results suggest that the porous Fe-Al intermetallics are promising materials for applications in harsh environments with a high-temperature sulfide-bearing atmosphere, such as in the coal chemical industry.

Fabrication of a Porous Fe–Al Intermetallic Alloy with Ultrahigh Open Porosity

“…[48] It was also presented that the compressive strength was %28 and %23 MPa, when the porosity was %54% and %62%, respectively. [21] Certainly, the compressive strength of the 1250 °C-sintered Fe-Al compacts in this work was lower than that with lower porosity in the literature. According to the Gibson-Ashby model, [49] the compression performance decreased with the increase of porosity.…”

“…It was noted that the porous Fe-Al intermetallic materials are usually used as the filtrator and separator. Published work suggests that the minimum compressive strength for the intermetallic materials applied to filtration and separation should be >10 MPa, [21,[45][46][47] implying that the porous Fe-Al alloy in this study could meet the requirement in terms of the compressive performance. In addition, the compressive strengths of the samples in this study and other investigations were compared.…”

“…The open porosity of the porous Fe-Al intermetallic alloy prepared in our work has also increased by %10% with respect to the TE reaction. [21,22] As for contrasting with space holder method [25][26][27]44] (e.g., NaCl and organic compounds as the porogen), the open porosity was increased by %11.12% to %34.96%.…”

“…[6,7,10] Thus, they have been recently considered as promising filtration and separation candidates operating in harsh environments. [11][12][13][14][15][16] Different kinds of methods have been developed to prepare porous Fe-Al intermetallic materials, including reactive synthesis method, [4,8,[17][18][19][20] thermal explosion (TE) method, [21][22][23][24] and space holder method. [25][26][27] Reactive synthesis method has been widely used to produce porous Fe-Al intermetallic materials.…”

3D‐Printed Multilayered Reinforced Material System for Gas Supply in CubeSats and Small Satellites

“…Advanced engineering materials play critical role in many fields of technology, ranging from space applications to many other fields . In recent decades, the space industry has demonstrated notable enthusiasm for small missions and ongoing advances in the manufacturing of space systems by small private companies, which take advantage of innovations made in other areas of science and technology.…”