Highly-porous FeAl intermetallic foams formed via sintering with Eosin Y as a gas releasing agent

FeAl intermetallic foams were formed via Eosin Y assisted sintering of iron and aluminum elemental powders. Due to the decomposition of Eosin Y, an acidic organic compound which molecule has benzene and pyran rings, foam with porosity of 49.4% was obtained (5wt% of Eosin Y as additive). The elemental mapping points out traces of carbon at pores bottoms, confirming assumption that additives combustion works as a foaming process. Pressure drop of the formed FeAl intermetallic foams was greater than for FeAl intermetallic foams formed without additives and crystalline oxalic acid as additive. Thus, the obtained foams may be useful as key material in the filtration and purification systems. •Eosin Y was used during Fe and Al elemental powders sintering.•Highly-porous Fe-Al intermetallic foam was formed.•Traces of carbon were found at pore bottoms.•The more Eosin Y as additive, the greater porosity, up to 49.4%.