Rapid fabrication and corrosion behavior of 3D-porous Cu-Al-Si compounds via low-energy self-exothermic reaction

With the increasing awareness of environmental protection, the requirements for realizing liquid-solid and gas-solid filtration and separation across various fluids in the fields of petrochemistry, gas purification，and aerospace are getting higher and higher, and the service environments of materials are getting more and more complicated. High-temperature gas purification often occurs in complex environments with high temperatures and pressures. This application requires gas filtration and purification equipment has good resistance to high-temperature durability and adapts to complex environmental changes with excellent mechanical properties. Similarly, materials are often used in harsh environments such as acid and alkali solutions in the solid-liquid separation process, so corrosion resistance is also important in the process. Porous intermetallic compounds exhibit the combined advantages of porous metals and ceramics, stemming from their distinctive covalent and metallic bonds. These compounds inherit the gloss, high strength, and hardness of metallic materials, along with the high-temperature and corrosion resistance of ceramics, making them suitable for use in extremely harsh environments.

Currently, research on porous CuAl intermetallics primarily concentrates on enhancing open porosity, controlling pore morphology, and understanding the IMC interfacial growth mechanisms. However, there are a few kinds of research related to the addition of the third group of components to optimize the properties of the Cu-Al system. Research indicates that incorporating modest quantities of third elements (such as Si, Cr, and Mo) can augment the resistance of Al-based alloys to high-temperature oxidation and corrosion, highlighting the synergistic interplay between these elements.

In this study, porous Cu-Al-Si intermetallics were synthesized by an efficient TE reaction, resulting in the retention of the original shape of the precursors. A comprehensive investigation was conducted on the effects of Si alloying in porous Cu-Al-Si samples on the heat explosion reaction process, microscopic structure, mechanical properties, and oxidation/corrosion resistance. An in-depth analysis of the antioxidant mechanism of Cu-Al-Si intermetallics to promote the understanding of the antioxidant properties of Al-containing intermetallic compounds.

Fig. 1 Stress-strain curve: (a) Cu-Al, (b) Cu-Al-Si.

Fig. 2 FE-SEM and EDS images of oxidation product at 800 ℃: (a-b) Cu-Al; EDS spectra of Cu, Al, and O in (b1-b3), (c-d) Cu-Al-Si, EDS spectra of Cu, Al, O and Si in (d1-d4).

Fig. 3 (a) Open-circuit potential curve of the sample, (b) Nyquist diagram of the sample.

Title: Rapid fabrication and corrosion behavior of 3D-porous Cu-Al-Si compounds via low-energy self-exothermic reaction

Authors: Zixuan Pang¹, Zhichao Shang¹, Xuewei Xu, Weijia Guo, Bowen Tang, Farid Akhtar, Baojing Zhang, Jianzhong Wang, Xiaoping Cai^*, Peizhong Feng^*

Link: https://www.sciencedirect.com/science/article/pii/S0925838824037861

DOI: https://doi.org/10.1016/j.jallcom.2024.177198

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