Effects of Particle Size and Forming Pressure on Pore Properties of Fe-Cr-Al Porous Metal by Pressureless Sintering

With increased hydrogen consumption in ammonia production, refining and synthesis, fuel cells and vehicle industries, development of the material components related to hydrogen production is becoming an important factor in industry growth. Porous metals for fabrication of hydrogen are commonly known for their relative excellence in terms of large area, lightness, lower heat capacity, high toughness, and permeability. Fe-Cr-Al alloys not only have high corrosion resistance, heat resistance, and chemical stability but also ductility, excellent mechanical properties. In order to control powder size and sintering temperature effects of Fe-Cr-Al porous metal fabrication, Fe-Cr-Al powder was classified into 25-35 mu m, 35-45 mu m, 45-75 mu m using an auto shaking sieve machine and then classified Fe-Cr-Al powders were pressed into disk shapes using a uniaxial press machine and CIP. The pelletized Fe-Cr-Al specimens were sintered at various temperatures in high vacuum. Properties such as pore size, porosity, and air permeability were evaluated using perm-porosimetry. Microstructure and phase changes were observed with SEM and XRD. Porosity and relative density were proportionated to increasing sintering temperature. With sufficient sintering at increasing temperatures, the pore size is expected to be gradually reduced. Porosity decreased with increasing sintering temperature and gradually increased necking of the powder.