FeCrAl Sintered Fiber Felt

FeCrAl Sintered Fiber Felt: Introduction and Applications

FeCrAl sintered fiber felt is a high-performance porous material composed of iron-chromium-aluminum (FeCrAl) alloy fibers, bonded through sintering to form a durable, heat-resistant structure. It combines the advantages of metal fibers (high strength, thermal conductivity) with ceramic-like oxidation resistance, making it ideal for extreme environments.

1. Material Composition & Properties

Key Components

Base Alloy: Fe-20Cr-5Al (typical), with minor additions of Y (yttrium) or Zr (zirconium) for enhanced oxidation resistance

Fiber Diameter: 10–50 μm (adjustable for porosity control).

Density: 0.1–0.5 g/cm³ (lightweight with high void volume).

Outstanding Properties

High-Temperature Stability:

Continuous use up to 1,300°C (in oxidizing atmospheres).

Forms a protective Al₂O₃ layer to prevent further oxidation.
✔ Thermal Shock Resistance:

Withstands rapid temperature cycling (e.g., 1,000°C ↔ room temperature).
✔ Corrosion Resistance:

Resists sulfur, carbon, and chlorine environments (vs. Ni-based alloys).
✔ Tailorable Porosity: 75–95% open porosity for gas/liquid permeability.

2. Manufacturing Process

Fiber Production: Melt-spun FeCrAl fibers are cut to desired lengths.

Felt Formation: Fibers are layered and needle-punched to create a 3D network.

Sintering: Heated in a vacuum or hydrogen atmosphere at 1,100–1,300°C to bond fibers.

Post-Treatment: Optional calendaring (for density control) or surface coating (e.g., Al₂O₃).

3. Applications

(1) High-Temperature Filtration

Industrial Furnaces: Capture particulate matter in exhaust gases (e.g., steel plants).

Power Plants: Filter fly ash in coal-fired boilers (replaces ceramic filters).

(2) Catalysis & Chemical Processing

Catalyst Supports: Porous substrate for catalytic converters (e.g., automotive exhaust).

Reactor Beds: Gas diffusion layers in hydrogen production or syngas reactors.

(3) Energy Storage & Conversion

Solid Oxide Fuel Cells (SOFCs): Anode support material due to redox stability.

Thermal Insulation: For kilns, reactors, and aerospace components.

(4) Acoustic & EMI Shielding

Aerospace: Engine compartment liners for noise reduction.

Electronics: Lightweight EMI shielding in high-temperature devices.

(5) Flame Arrestors & Safety

Oil/Gas Industry: Prevents flame propagation in pipelines and vents.

4. Advantages Over Alternatives

5.Selection Guidelines

For Filtration: Choose high porosity (90%) + fine fibers (10μm).

For Catalysis: Opt for surface-activated coatings (e.g., γ-Al₂O₃).

For Insulation: Use multi-layer felt with graded density.

Tip: Request pressure drop vs. flow rate curves and cyclic oxidation test data for critical applications.

FeCrAl sintered fiber felt bridges the gap between metals and ceramics, offering unmatched durability in aggressive environments.