Abstract
Fe foam with above 90% porosity and 2 millimeter pore size was successfully fabricated by a slurry coating process. In this study, the binder contents were controlled to produce the Fe foam with different pore size, strut thickness and porosity. Firstly, the slurry was prepared by uniform mixing with Fe powders, distilled water and polyvinyl alcohol (PVA) as initial materials. After slurry coating on the polyurethane (PU) foam the sample was dried at 80°C. The PVA and PU foams were then removed by heating at 700°C for 3 hours. The debinded samples were subsequently sintered at 1250°C with holding time of 3 hours under hydrogen atmosphere. The three dimensional geometries of the obtained Fe foams with open cell structure were investigated using X-ray micro CT(computed tomography) as well as the pore morphology, size and phase.
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