Chromium-Aluminum Alloyed Ni-Foam for High Temperature Oxidation Resistance

Tailored compositions of alloyed Ni-foams are progressively investigated in applications such as heat exchangers, cooling struts and filters. In the present work, commercially pure Ni-foam is alloyed using different methods including slurry and dry powder pack coating processes with various compositions. The slurry consists of source material powder mixed with an activator and an organic water based binder. The dry mix is composed of the source powder mixed with the activator and an inert powder as filler. Chromium and or aluminum were coated and diffused into the strut walls of the foam upon heat treatment and the success of different methods in alloy formation was compared. Mechanical properties and high temperature oxidation resistance of the alloyed foams were investigated.