Fecralloy coating layer with large surface area is suitable for use as a filter media for efficient removal of hot gaseous pollutants exhausted from combustion processes. For uniform preparation of a Fecralloy coating layer with large surface area and strong adhesion to substrate, electrospray coating and thermal treatment processes are experimentally optimized in this study. A nano-colloidal solution with 0.05 wt% Fecralloy nanoparticles is successfully prepared. Optimized electrospraying conditions are experimentally discovered to prepare a uniform coating layer of Fecralloy nanocolloidal solution on a substrate. Drying the electrospray coated Fecralloy nano-colloidal solution layer at 120oC and subsequent heating at 600oC are the best post-treatment for enhancing the adhesion force and surface roughness of the Fecralloy coating layer on a substrate. An electrospray coating system, consisting of several multi-groove nozzles, is also experimentally confirmed as a reasonable device for uniform coating of Fecralloy nano-colloid on a large area substrate

The porous metals are known as relatively excellent characteristic such as large surface area, light, lower heat capacity, high toughness and permeability. The Fe-Cr-Al alloys have high corrosion resistance, heat resistance and chemical stability for high temperature applications. And then many researches are developed the Fe-Cr-Al porous metals for exhaust gas filter, hydrogen reformer catalyst support and chemical filter. In this study, the Fe-Cr-Al porous metals are developed with Fe-22Cr-6Al(wt) powder using powder compaction method. The mean size of Fe-22Cr-6Al(wt) powders is about 42.69 μm. In order to control pore size and porosity, Fe-Cr-Al powders are sintered at 1200~1450oC and different sintering maintenance as 1~4 hours. The powders are pressed on disk shapes of 3 mm thickness using uniaxial press machine and sintered in high vacuum condition. The pore properties are evaluated using capillary flow porometer. As sintering temperature increased, relative density is increased from 73% to 96% and porosity, pore size are decreased from 27 to 3.3%, from 3.1 to 1.8 μm respectively. When the sintering time is increased, the relative density is also increased from 76.5% to 84.7% and porosity, pore size are decreased from 23.5% to 15.3%, from 2.7 to 2.08 μm respectively.

Metallic porous materials have many interesting combinations of physical and geometrical properties with very low specific weight or high gas permeability. In this study, highly porous Cu foam is successfully fabricated by a slurry coating process. The Cu foam is fabricated specifically by changing the coating amount and the type of polyurethane foam used as a template. The processing parameters and pore characteristics are observed to identify the key parameters of the slurry coating process and the optimized morphological properties of the Cu foam. The pore characteristics of Cu foam are investigated by scanning electron micrographs and micro-CT analyzer, and air permeability of the Cu foam is measured by capillary flow porometer. We confirmed that the characteristics of Cu foam can be easily controlled in the slurry coating process by changing the microstructure, porosity, pore size, strut thickness, and the cell size. It can be considered that the fabricated Cu foams show tremendous promise for industrial application.