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In this paper, fabrication of open-celled porous Fe-10%Al foam by space-holder technique in which NaCl powder and polyester resin were utilized as space holder and binder respectively to generate 30-80% porosities was studied. FeAl solid solution was prepared via mechanical alloying method after 25 h high energy milling process. The results indicate that the size and shapes of the pores are determined by the size and shapes of NaCl particles. Also, when compaction pressure was in the range of 70-150 MPa and the sintering process was performed at temperature around 1100◦C, the samples had the best quality. Microstructure observations show the pore size was in the range of 200-500 μm.

Fabrication of Open Cell Fe-10%Al Foam by Space-Holder Technique