The Effect of Mg Content on the Microstructure and Open Porosity of a Porous FeAl Intermetallic Compound

In this study, a porous FeAl intermetallic compound with high porosity was synthesized via vacuum sintering using Mg powder as a pore-forming agent, leveraging its high saturated vapor pressure and almost non-reactivity with Fe. The influence of the addition of Mg powder on pore characteristics and microstructure evolution was systematically investigated. The results indicate that variations in Mg content within sintered compacts exhibit a negligible impact on primary phase composition, with the FeAl phase remaining predominant. However, excessive initial Mg content induces the encapsulation of the FeAl phase by minor Fe2Al5 and Al3Mg2 phases, compromising the phase’s purity. The porosity positively correlates with Mg content, and porous material with a porosity of 72.8% is obtained (40 at.% of Mg as an additive). Moreover, the pore structure manifests as an interconnected hole morphology. These findings provide valuable insights for further exploration of the design of porous FeAl material and its performance enhancement in emerging applications.