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A novel sintered cutting stainless steel fiber felt with internal channels (SCSSFFC) composed of a stainless-steel fiber skeleton, three-dimensional interconnected porous structure and multiple circular microchannels is developed. SCSSFFC has a jagged and rough surface morphology and possesses a high specific surface area, which is approximately 2.4 times larger than that of the sintered bundle-drawing stainless steel fiber felt with internal channels (SBDSSFFC) and is expected to enhance adhesive strength. The sol-gel and wet impregnation methods are adopted to prepare SCSSFFC with an Al₂O₃ coating (SCSSFFC/Al₂O₃). The adhesive strength of SCSSFFC/Al₂O₃ is investigated using ultrasonic vibration and thermal shock tests. The experimental results indicate that the weight loss rate of the Al₂O₃ coating has a 4.2% and 8.42% reduction compared with those of SBDSSFFCs based on ultrasonic vibration and thermal shock tests. In addition, the permeability of SCSSFFC/Al₂O₃ is investigated based on forced liquid flow tests. The experimental results show that the permeability and inertial coefficients of SCSSFFC/Al₂O₃ are mainly affected by the coating rate, porosity and open ratio; however, the internal microchannel diameter has little influence. It is also found that SCSSFFC/Al₂O₃ yields superior permeability, as well as inertial coefficients compared with those of other porous materials reported in the literature.

Fabrication and Characteristics of Sintered Cutting Stainless Steel Fiber Felt with Internal Channels and an Al2O3 Coating