A new PM process for manufacturing of alloyed foams for high temperature applications

Metallic foams are interesting candidates for a wide range of applications in the field of energy- and filtration technologies as well as catalyst carriers. Depending on the operating conditions, the material has to meet outstanding high temperature properties, corrosion resistance, low back pressure or high specific surface. A pilot production based on a new PM technology was established which allows to tailor material properties like pore size and alloy composition over a wide range for different applications. The powder metallurgical method is described which transforms a pure metal foam substrate into a highly alloyed foam material. Especially for exhaust after-treatment or reforming processes, nickel and iron based alloys containing chromium and aluminium are candidates because of their superior oxidation resistance. Various examples will be presented demonstrating the flexibility of the process in terms of materials and sample design as well as properties of the foam and prototypes are given.