Wojciech J. Stępniowski

Fabrication of Fe-Al Intermetallic Foams via Organic Compounds Assisted Sintering

The influence of the addition of organic compounds, such as palmitic acid and cholesteryl myristate, on the porous structure of Fe-Al intermetallics formation has been investigated in detail in this paper. It was found that additives have a significant effect on the final porosity of the obtained sinters. Formed gaseous products from combustion play the role of the foaming agent during Fe-Al intermetallic alloy sintering. The influence of these additives is also clearly noticeable in chemical composition changes of the final products through the increase of carbon content in the porous structure. This is attributed to the thermal decomposition, namely combustion, of the organic additives.

Fabrication and geometric characterization of highly-ordered hexagonally arranged arrays of nanoporous anodic alumina

Abstract Anodic aluminum oxide (AAO) has been fabricated in the 0.3 M oxalic acid at voltage range 20-60 V and temperature range of 35-50oC. The resulting nanoporous alumina surfaces were characterized by high resolution scanning electron microscopy, and the images were quantitatively analysed by means of an innovative approach based on fast Fourier transform. The influence of operating anodization voltage and electrolyte temperature on nanopores geometry (pore diameter, interpore distance, porosity, pores density) and arrangement has been studied in details and compared to literature data and theoretical calculations. It was found that independently from the temperature, the best arrangement of the nanopores is for anodic aluminum oxide formed at voltages ranging from 40 to 50 V. Moreover, it was found that pore diameter and interpore distance increase linearly with voltage, what is in line with the literature data.

Advanced Image Analysis of the Surface Pattern Emerging in Ni3Al Intermetallic Alloys on Anodization

Anodization of Ni3Al alloy is of interest in the field of industrial manufacturing, thanks to the formation of protective oxide layer on the materials working in corrosive environments and high temperatures. However, homogeneous surface treatment is paramount for technological applications of this material. The anodization conditions have to be set outside the ranges of corrosion and “burning”, which is the electric field enhanced anodic dissolution of the metal. In order to check against occurrence of these events, proper quantitative means for assessing the surface quality have to be developed and established. We approached this task by advanced analysis of scanning electron microscope images of anodized Ni3Al plates. The anodization was carried out in 0.3 M citric acid at two temperatures of 0 and 30°C and at voltages in the range of 2 12 V. Different figures can be used to characterize the quality of the surface, in terms of uniformity. Here, the concept of regularity ratio spread is used for the first time on surfaces of technological interest. Additionally, the Minkowski parameters have been calculated and their meaning is discussed.

Decomposition of Cyclohexane on Ni3Al Thin Foil Intermetallic Catalyst

Micro-grained thin foils made of Ni3Al intermetallic alloy were fabricated, according to a previously described procedure, and tested as catalyst for decomposition of cyclohexane. The conversion efficiency of the catalyst was evaluated in a synthetic air atmosphere, and found to be as high as 98.7% ± 1.0% at 600 °C and 86.7% ± 3.6% at 500 °C. During the reaction, the growth of carbon nanofibers on the catalysts surface was observed. The chemical and phase composition of the nanofibers was investigated with scanning electron microscopy (SEM), energy dispersive spectrometry (EDS) and X-ray diffraction (XRD), finding them to be made of graphitic carbon. Additionally, nanoparticles of nickel appear to be incorporated in the fibers. The obtained material is promising for large scale fabrication in industrial applications because of its high efficiency in the hydrocarbon decomposition, the simple fabrication procedure, and the form of self-supporting foils with the presence of additional carbon nanofibers that increase its efficiency.

Amino Acids Aided Sintering for the Formation of Highly Porous FeAl Intermetallic Alloys

Fabrication of metallic foams by sintering metal powders mixed with thermally degradable compounds is of interest for numerous applications. Compounds releasing gaseous nitrogen, minimizing interactions between the formed gases and metallic foam by diluting other combustion products, were applied. Cysteine and phenylalanine, were used as gas releasing agents during the sintering of elemental Fe and Al powders in order to obtain metallic foams. Characterization was carried out by optical microscopy with image analysis, scanning electron microscopy with energy dispersive spectroscopy, and gas permeability tests. Porosity of the foams was up to 42 ± 3% and 46 ± 2% for sintering conducted with 5 wt % cysteine and phenylalanine, respectively. Chemical analyses of the formed foams revealed that the oxygen content was below 0.14 wt % and the carbon content was below 0.3 wt %. Therefore, no brittle phases could be formed that would spoil the mechanical stability of the FeAl intermetallic foams. The gas permeability tests revealed that only the foams formed in the presence of cysteine have enough interconnections between the pores, thanks to the improved air flow through the porous materials. The foams formed with cysteine can be applied as filters and industrial catalysts.

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.