Highly porous open cellular TiAl-based intermetallics fabricated by thermal explosion with space holder process

• TiAl-based materials were prepared by an energy and time saving method of TE.
• Highly porous materials were obtained via space holder process.
• Porous materials possess a bimodal structure.
• The large pores replicated the characteristics of NaCl particles.

High porosity TiAl-based intermetallics were prepared through thermal explosion (TE) from Ti–50Al at.% powders with NaCl as soluble template. The results showed that the space holder particles of NaCl were removed completely in green compacts, and porous Ti–Al materials were synthesized via a low-energy consumption method of TE at a temperature of 600 °C. TiAl was evolved as dominant phase in sintered materials at 1100 °C. With adding 80 vol.% NaCl to Ti–50Al at.% powders, the open porosity was significantly elevated up to 84%. Moreover, the porous materials exhibited a bimodal pore size distribution: large pores (200–500 μm) replicating NaCl particles and small pores (<50 μm) embedded in pore walls. The interconnected small and large pores make open cellular porous TiAl materials, which prescribe them promising for a wide range of applications in separation, heat insulation and catalysis.

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