Pseudo-binary reactive synthesis of porous multi-component alloys

Porous multicomponent alloys, as pivotal functional materials, hold great promise for applications in environmental protection and energy conversion fields. In order to address the challenges posed by powder moldability, fast sintering, composition control and pore-structure regulation of porous multi-component alloys, this work proposed a pseudo-binary reactive synthesis method, in which raw powder materials were categorized into two groups based on the characteristics including melting point, hydrogen reducibility, solubility and burn-off susceptibility. By this method, the process characteristics involving moldability, thermal effects, diffusion reactions and kinetics, pore structure and element recovery of porous FeCrNiAl alloys were investigated and compared with those by traditional mixed elemental powders method. The results showed that pseudo-binary reactive synthesis stood out in the aspects of processability, pore structure uniformity, ingredient controllability and application performance. Additionally, this method can be further extended to prepare multi-elemental alloy porous materials with hexary elemental components.