Porous materials have attracted significant attention in the scientific community due to their unique properties and various applications. For example, porous materials are crucial in gas or liquid stream adsorption and purification processes (including catalytic purification). Porous materials can be composed of different materials, such as metals, ceramics, polymers, and composites. Among them, porous metals have been widely studied for their excellent properties, such as high strength, good thermal conductivity, and excellent biocompatibility. However, porous metals have poor corrosion resistance and are challenging to prepare microfiltration-grade porous bodies. And porous ceramic materials have excellent high-temperature anti-oxidation and strength. However, they have several disadvantages such as high brittleness, low elasticity, poor alkali corrosion resistance, and poor thermal shock resistance, which may result in damage during the secondary cycle, posing a risk to the production process.

In recent years, porous intermetallic compounds (PICs) have gained considerable attention as they combine the benefits of intermetallic compounds with the unique properties of porous materials. Porous intermetallic compounds are a class of materials that are characterized by their ordered atomic arrangements, making them structurally distinct from their amorphous and crystalline counterparts. Due to their distinct mechanical, thermal, and catalytic properties, Co-Al PICs have attracted considerable interest. Co-Al PICs have various industrial applications, such as producing magnetic materials, hard coatings, and hydrogen storage. However, the corrosion resistance of Co-Al intermetallic compounds at high temperatures remains a challenge. The previous researches revealed that by adding the third elements (Cr, Si and Fe), it could be enhanced the high-temperature mechanical and anti-oxidation of Al-based alloy, which reflecting the classical reactive element (RE) effect.

This work has used a simple and efficient TE method to prepare porous Co-Al-Fe intermetallic compounds with high porosity for high-temperature and corrosive environments. The effects of the adding different contents of Fe on the TE reaction process, pore structure, mechanical properties and oxidation/sulphuration properties of the Co-Al system were investigated in detail. Moreover, the diffusion reaction of the Co-Al-Fe as well as the evolution of microstructure during the TE reaction was investigated. This research offers a promising strategy for the synthesis of porous intermetallic compounds for high-temperature gas filtration and alkylation reactions.

Fig. 1. EPMA results of sample CA-15Fe sintered at temperatures of (a-d) 530 °C for 30 minutes and (e-h) 1000 °C for 1 hour.

Fig. 2. (a) The porosity results were calculated using the reconstructed model. (b) Areal porosity of CA-15Fe is figured on Z slices perpendicular to the XY axis. (c) Pores network model (PNM) of the CA-15Fe.

Fig. 3. FE-SEM micrograph of CA-15Fe after sulfidation at 900°C for 120 hours and EDS mapping.

Title: The effect of Fe in the rapid thermal explosion synthesis and the high-temperature corrosion behavior of porous Co-Al-Fe intermetallic

Authors: Zhichao Shang, Xiaoping Cai**,  Farshid Pahlevani, Yan Zheng, Akbar Hojjati-Najafabadi, Xinran Gao, Baojing Zhang, Peizhong Feng* 

Link: https://www.sciencedirect.com/science/article/pii/S0010938X23006819

DOI: https://doi.org/10.1016/j.corsci.2023.111638

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