Fabrication and Characteristics of Sintered Cutting Stainless Steel Fiber Felt with Internal Channels and an Al2O3 Coating

A novel sintered cutting stainless steel fiber felt with internal channels (SCSSFFC) composed of a stainless-steel fiber skeleton, three-dimensional interconnected porous structure and multiple circular microchannels is developed. SCSSFFC has a jagged and rough surface morphology and possesses a high specific surface area, which is approximately 2.4 times larger than that of the sintered bundle-drawing stainless steel fiber felt with internal channels (SBDSSFFC) and is expected to enhance adhesive strength. The sol-gel and wet impregnation methods are adopted to prepare SCSSFFC with an Al₂O₃ coating (SCSSFFC/Al₂O₃). The adhesive strength of SCSSFFC/Al₂O₃ is investigated using ultrasonic vibration and thermal shock tests. The experimental results indicate that the weight loss rate of the Al₂O₃ coating has a 4.2% and 8.42% reduction compared with those of SBDSSFFCs based on ultrasonic vibration and thermal shock tests. In addition, the permeability of SCSSFFC/Al₂O₃ is investigated based on forced liquid flow tests. The experimental results show that the permeability and inertial coefficients of SCSSFFC/Al₂O₃ are mainly affected by the coating rate, porosity and open ratio; however, the internal microchannel diameter has little influence. It is also found that SCSSFFC/Al₂O₃ yields superior permeability, as well as inertial coefficients compared with those of other porous materials reported in the literature.