Highly Porous Open Cell Nickel Chromium Aluminum Foam
Introduction
- Nickel chromium aluminum foam (Ni‑Cr‑Al foam) is a 3D open‑cell metal foam with high porosity, low density and excellent high‑temperature oxidation resistance. Its interconnected Ni‑Cr‑Al skeleton provides a large specific surface area and uniform gas flow channels, making it ideal for use in radiant burners, catalytic combustion, reformer burners and high‑temperature gas distribution or filtration. The material can be cut, machined and formed into custom sizes for laboratory testing and industrial furnace or burner designs.
- Thanks to the combined effects of Ni, Cr and Al, Ni‑Cr‑Al foam offers good mechanical stability and corrosion resistance in hot, oxidizing atmospheres and many combustion gases. It is widely used as a support for high‑temperature catalysts, burner cores, flame stabilizers, VOC treatment units and heat‑exchange structures in petrochemical, metallurgy, power and environmental engineering. Using nickel chromium aluminum foam helps improve heat and mass transfer, achieve more uniform combustion, reduce emissions and extend the service life of thermal equipment.
Spécifications
| Type | Open‑cell Ni‑Cr‑Al alloy foam / nickel‑chromium‑aluminum porous metal foam (high‑temperature, oxidation‑resistant alloy) |
| Purity / Alloy Base | Ni‑Cr‑Al alloy system (nickel as main component with chromium and aluminum as key alloying elements; Cr and Al contents, plus possible minor elements, are adjusted to optimize high‑temperature oxidation resistance, mechanical strength and thermal stability, depending on specific grade) |
| Formulaire | Sheet, plate, strip, block, roll or custom‑cut parts; can be supplied as bulk Ni‑Cr‑Al foam or as Ni‑based foam with Ni‑Cr‑Al surface alloy / coating produced by alloying, sintering or other metallurgical processes, according to application requirements |
| Taille des cellules (PPI) | Commonly around 10–60 PPI (pores per inch) for thermal and catalytic applications; coarse (10–20 PPI), medium (20–40 PPI) and fine (40–60 PPI) structures are available; other pore sizes and gradients can be customized on request |
| Épaisseur | Typical foam sheets approx. 1–30 mm for catalyst supports, burners and high‑temperature filters; thinner foams for low‑pressure‑drop heat‑transfer elements, thicker sections for burner cores, structured catalysts and energy‑absorbing components; customized thickness available according to design requirements |
| Taille et forme | Standard sheets and blocks (e.g. 50 × 50 mm, 100 × 100 mm, 200 × 300 mm) and discs or rings; can be cut, punched, machined or formed into plates, cylinders, panels and other geometries based on customer drawings or CAD models for reactors, furnaces, burners and heat‑exchange modules |
| Porosité | Typically about 70% – 95% (adjustable); lower porosity for higher strength and load‑bearing capacity, higher porosity for larger surface area, better gas/liquid permeability and heat/mass transfer; porosity tailored to catalytic combustion, filtration or thermal‑management applications |
| Taux de cellules ouvertes | Usually ≥ 90% open‑cell interconnected structure, providing continuous channels for gas or liquid flow, uniform gas distribution and efficient mixing; degree of interconnectivity depends on manufacturing process and pore size |
| Densité volumique | Approx. 0.3–1.5 g/cm³ (adjustable via porosity and structure), much lower than dense Ni‑Cr‑Al alloys while maintaining metallic connectivity and mechanical strength for self‑supported structures and burner cores |
| Densité de surface | Depending on thickness and porosity, typically about 300–10,000 g/m²; lighter foams for low‑mass thermal and catalytic elements, heavier foams for robust structural catalyst carriers and high‑load burner or radiant panels |
| Specific Surface Area | Large effective surface area due to 3D Ni‑Cr‑Al skeleton (commonly several hundred to several thousand m²/m³, depending on pore size and porosity), providing ample active surface for catalytic reactions, heat transfer and contact processes in high‑temperature gas streams |
| Thermal Conductivity (Effective) | Effective thermal conductivity lower than dense Ni‑Cr‑Al / Ni‑Cr alloys due to porosity (typically on the order of a few to tens of W/m·K, strongly dependent on porosity and structure), suitable for high‑temperature heat‑exchange, radiant burners and thermal‑management components |
| Electrical Conductivity | Good metallic conductivity, reduced compared with dense nickel‑based alloys due to pores and alloying elements, but sufficient for ignition, heating, grounding and certain electrothermal or catalytic applications where conductive supports are required |
| Mechanical Strength (Compressive) | Compressive strength depends on porosity and pore architecture; typically from a few MPa up to more than 10 MPa for common engineering‑grade foams; higher‑density foams exhibit higher strength and stiffness, while higher‑porosity foams provide better flow characteristics and energy absorption |
| Average Tensile Strength (N/20 mm) | Porous Ni‑Cr‑Al foam generally shows lower tensile strength than dense alloys; thin strips typically reach tens of N/20 mm, depending on porosity and orientation. Actual values should be verified for each specific product, thickness and application |
| Temperature Resistance | Designed for operation in hot, oxidizing gas environments at elevated temperatures; Ni‑Cr‑Al alloys are widely used for heat‑resistant and oxidation‑resistant parts. Ni‑Cr‑Al foam can be applied in burners, radiant panels, catalytic combustion and heat‑treatment systems at high temperatures (exact limits depend on alloy composition, gas atmosphere and mechanical load) |
| Apparence | Metallic gray to gray‑silver Ni‑Cr‑Al surface with 3D sponge‑like open‑cell structure; generally uniform pore distribution without obvious defects such as large blind holes, cracks or severe deformation. Surface can be supplied cleaned, oxidized or pre‑treated for coating and catalytic loading |
| Chemical Composition | Ni‑Cr‑Al alloy (nickel‑based with chromium and aluminum) or Ni foam with Ni‑Cr‑Al surface alloy layer, depending on manufacturing route; Ni provides basic conductivity and strength, Cr significantly improves high‑temperature oxidation and corrosion resistance, Al further enhances oxidation resistance, reduces density and can influence catalytic behavior; exact composition defined by product grade or customer specification |
| Corrosion & Oxidation Resistance | Excellent oxidation resistance at elevated temperatures and in many combustion gases due to combined Cr and Al; suitable for use in high‑temperature air, flue gases and various furnace/combustion atmospheres. For very aggressive or special chemical environments, compatibility should be evaluated and additional coatings may be required |
| Flexibilité | Thin and medium‑porosity foams can be slightly bent, rolled or compressed; stiffness and brittleness increase with thickness and lower porosity. Repeated sharp bending may cause local fracture of the foam skeleton, so handling should follow high‑temperature structural‑foam guidelines |
| Elongation Rate (%) | Macroscopic elongation is limited compared with dense ductile alloys because of the porous network, typically a few percent level depending on structure and direction; design should primarily rely on compressive and bending performance for structural and thermal applications |
| Processability | Can be cut, punched, laser‑cut, machined and formed; can be brazed, welded (where applicable) or mechanically fixed into assemblies. Surface is suitable for wash‑coating, impregnation, thermal spraying and other catalyst‑loading or protective‑coating processes used in high‑temperature reactors and burners |
| Surface Treatment / Coating (Optional) | Optional treatments include degreasing, controlled oxidation, ceramic wash‑coating, and catalytic layers (e.g. Ni‑, Co‑ or noble‑metal catalysts, perovskites) as well as protective coatings to enhance thermal shock resistance, catalytic activity and service life in severe operating conditions |
| Typical Electrochemical / Catalytic Applications | High‑temperature catalyst supports for reforming, oxidation and combustion; structured catalysts for VOC abatement, exhaust treatment and gas‑phase reactions; porous burners, radiant burner cores, flame holders and ignition supports where uniform gas distribution and stable, low‑emission combustion are required |
| Other Industrial Applications | Lightweight heat‑exchange media, high‑temperature gas filters, flame stabilizers, gas distribution plates, noise‑ and energy‑absorbing structures, thermal‑management components and support structures in petrochemical, metallurgy, power generation, furnace and environmental engineering fields |
| Main Features & Advantages | Combines high porosity and large surface area with good metallic conductivity, relatively low density and outstanding high‑temperature oxidation resistance from Cr and Al; 3D interconnected network enables efficient heat and mass transfer with low pressure drop; suitable as a robust, lightweight support for catalysts, burners and thermal‑engineering components where conventional dense metals or ceramics are less efficient |
Dimension (Épaisseur* Longueur*Largeur)
| 0,08 mm × 300 mm × 200 mm | 0,2 mm × 200 mm × 300 mm | 0,3 mm * 200 mm * 300 mm |
| 0,5 mm × 200 mm × 300 mm | 0,7 mm × 200 mm × 300 mm | 0,9 mm × 200 mm × 300 mm |
| 1,0 mm × 200 mm × 300 mm | 1,3 mm × 200 mm × 300 mm | 1,5 mm × 200 mm × 300 mm |
| 1,7 mm × 200 mm × 300 mm | 2,0 mm × 200 mm × 300 mm | 5 mm × 200 mm × 300 mm |
| 10 mm × 200 mm × 300 mm | 30 mm × 200 mm × 300 mm | La taille peut être personnalisée. |
Pour personnaliser différentes mousses métalliques, veuillez cliquer sur l'image ci-dessous pour plus de détails :
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