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Content archived on 2024-06-10

Development of porous metal fiber components for various industrial high temperature applications


Objectives and content
In automobile, aircraft, and metallurgical industry,
highly porous components with pronounced high temperature
(HT) properties are needed. Present metal-based
solutions suffer from limited porosity, limited HT
properties due to only a small choice of metal
compositions, insufficient workability of the fibre
preforms, and a very high price. In case of ceramics,
high mechanical brittleness and high sensitivity to
thermal shock restrict the possible range of
applications. Moreover, joining of ceramic to metal still
remains a problem.
Therefore, the final objective of this industrial
research project is to develop, through innovative low
cost technology, a new generation of high temperature,
low-density porous metal fibre components. Substantial
cost savings of up to 40% and more are expected. A
significant increase in service temperature, time, and HT
strength and the comparably low cost of the final product
will provide innovative solutions to existing problems in
HT filtering, catalyst devices, and thermal shielding.
Porosities of up to 97% are expected to open up a whole
new field of applications for porous metal fibre
For the new components, a three-step process is to be
developed: Fibre production by melt extraction, preform
fabrication by bulk or textile techniques, preform
consolidation/shaping by sintering, brazing, or chemical
deposition. Unlike prevalent mechanical fibre production
techniques, melt extraction allows the production of
fibres from a large number of different alloys at
significantly lower cost. Alloy compositions include
intermetallics and the addition of noble elements. This
provides the basis for drastically improved HT mechanical
properties, oxidation resistance, and the possibility to
obtain intrinsic catalytic active elements. New preform
fabrication and consolidation technologies to produce
high workability, high porosity fibre structures are to
be developed. Further enhancement of HT properties
through metallic and ceramic coatings can be effected.
In order to test the performance of the new components,
three representative case studies have been selected:
thermal shields, catalytic converters and hot gas
filters. Prototype components for each of the above HT
applications will be manufactured and tested.
The consortium brings together 8 partners from 4 European
countries (Austria, Germany, Great Britain, and France).
The well-balanced composition of three end-users
(automobile, aircraft, metallurgy), one producer of semifinished products, one producer of fibres, and three
research and development institutes provides an excellent
chance to implement project results in actual
Brite/Euram III Areas covered by this proposal are
2.1.3.S 2.1.1.M 3B4.1S and 1.2.3.S.

Call for proposal

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Fraunhofer-Gesellschaft zur Förderungder Angewandten Forschung e.V.
EU contribution
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28,Winterbergstrasse 28
1277 Dresden

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Total cost
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Participants (7)