Fabrication of FeAl Intermetallic Foams by Tartaric Acid-Assisted Self-Propagating High-Temperature Synthesis

Iron aluminides are intermetallics with interesting applications in porous form thanks to their mechanical and corrosion resistance properties. However, making porous forms of these materials is not easy due to their high melting points. We formed FeAl foams by elemental iron and aluminum powders sintering with tartaric acid additive. Tartaric acid worked as an in situ gas-releasing agent during the self-propagating high-temperature synthesis of FeAl intermetallic alloy, which was confirmed by X-ray diffraction measurements. The porosity of the formed foams was up to 36 ± 4%. In the core of the sample, the average equivalent circle diameter was found to be 47 ± 20 µm, while on the surface, it was 35 ± 16 µm; thus, the spread of the pore size was smaller than reported previously. To investigate functional applications of the formed FeAl foam, the pressure drop of air during penetration of the foam was examined. It was found that increased porosity of the material increased the flow of the air through the metallic foam.