Porous metals demonstrate not only excessively low densities, but also novel physical, thermal, mechanical, electrical, and acoustic properties. Thus, porous metals exhibit exceptional performance, which are useful for diesel particulate filters, heat exchangers, and noise absorbers. In this study, SUS316L foam with 90% porosity and 3,000 μm pore size is successfully manufactured using the electrostatic powder coating (ESPC) process. The mean size of SUS316L powders is approximately 12.33 μm. The pore properties are evaluated using SEM and Archimedes. As the quantity of powder coating increases, pore size decreases from 2,881 to 1,356 μm. Moreover, the strut thickness and apparent density increase from 423.7 to 898.3 μm and from 0.278 to 0.840 g/cm³, respectively. It demonstrates that pore properties of SUS316L powder porous metal are controllable by template type and quantity of powder coating.

The porous metals are known as relatively excellent characteristic such as large surface area, light, lower heat capacity, high toughness and permeability. The Fe-Cr-Al alloys have high corrosion resistance, heat resistance and chemical stability for high temperature applications. And then many researches are developed the Fe-Cr-Al porous metals for exhaust gas filter, hydrogen reformer catalyst support and chemical filter. In this study, the Fe-Cr-Al porous metals are developed with Fe-22Cr-6Al(wt) powder using powder compaction method. The mean size of Fe-22Cr-6Al(wt) powders is about 42.69 μm. In order to control pore size and porosity, Fe-Cr-Al powders are sintered at 1200~1450°C and different sintering maintenance as 1~4 hours. The powders are pressed on disk shapes of 3 mm thickness using uniaxial press machine and sintered in high vacuum condition. The pore properties are evaluated using capillary flow porometer. As sintering temperature increased, relative density is increased from 73% to 96% and porosity, pore size are decreased from 27 to 3.3%, from 3.1 to 1.8 μm respectively. When the sintering time is increased, the relative density is also increased from 76.5% to 84.7% and porosity, pore size are decreased from 23.5% to 15.3%, from 2.7 to 2.08 μm respectively.

Citations

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• Synthesis and Magnetic Hysteresis Properties of an Aluminum-Doped Isotropic Hard-Magnetic Fe–Cr–Co Powder Alloy
  A. S. Ustyukhin, V. A. Zelensky, I. M. Milyaev, M. I. Alymov, A. A. Ashmarin, A. B. Ankudinov, K. V. Sergienko
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• Fabrication of a Porous Ni-Based Metal with a Multi-pore Structure by a Screen Printing Process
  Yu-Jeong Yi, Min-Jeong Lee, Jung-Yeul Yun, Byoung-Kee Kim
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Fe-Cr-Al powder porous metal was manufactured by using new electro-spray process. First, ultra-fine fecralloy powders were produced by using the submerged electric wire explosion process. Evenly distributed colloid (0.05~0.5% powders) was dispersed on Polyurethane foam through the electro-spray process. And then degreasing and sintering processes were conduced. In order to examine the effect of cell size (200 μm, 450 μm, 500 μm) in process, pre-samples were sintered for two hours at temperature of 1450°C, in H₂ atmospheres. A 24-hour thermo gravimetric analysis test was conducted at 1000°C in a 79% N₂ + 21% O₂ to investigate the high temperature oxidation behavior of powder porous metal. The results of the high temperature oxidation tests showed that oxidation resistance increased with increasing cell size. In the 200 μm porous metal with a thinner strut and larger specific surface area, the depletion of the stabilizing elements such as Al and Cr occurred more quickly during the high-temperature oxidation compared with the 450, 500 μm porous metals.

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• Fabrication and Mechanical Properties of Open‐Cell Austenitic Stainless Steel Foam by Electrostatic Powder Spraying Process
  Tae-Hoon Kang, Kyu-Sik Kim, Jung-Yeul Yun, Min-Jeong Lee, Kee-Ahn Lee
  Advanced Engineering Materials.2020;[Epub]     CrossRef
• Microstructure and High Temperature Oxidation Behaviors of Fe-Ni Alloys by Spark Plasma Sintering
  Chae Hong Lim, Jong Seok Park, Sangsun Yang, Jung-Yeul Yun, Jin Kyu Lee
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• Effect of Al2O3 Inter-Layer Grown on FeCrAl Alloy Foam to Improve the Dispersion and Stability of NiO Catalysts
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  Korean Journal of Materials Research.2015; 25(8): 391~397.     CrossRef

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• Synthesize of Nd₂Fe₁₄B Powders from 1-D Nd₂Fe₁₄B Wires using Electrospinning Process
  Nu Si A Eom, Su Noh, Muhammad Aneeq Haq, Bum Sung Kim
  Journal of Korean Powder Metallurgy Institute.2019; 26(6): 477.     CrossRef