Fiber Felts | Electrochemical Materials | CAPLINQ Corporation

Product Selector Guide

Item

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Porosity (%)

 Thickness (um)*

Basis Weight (g)

Actual weight (g)**

LINQCELL TFP250

 50 - 60

250

45.5

18.3 - 22.6

LINQCELL TFP250S

60 - 70

250

45.5

13.7 - 18.1

LINQCELL TFP400

50 - 60

400

72.8

29 - 36.3

LINQCELL TFP400S

60 - 70

400

72.8

22 - 29

LINQCELL TFP500

50-60

500

-

-

LINQCELL TFP600

50 - 60

600

109.3

44 - 54.5

LINQCELL TFP600S

60 - 70

600

109.3

32.8 - 43.6

LINQCELL TFP800

50 - 60

800

145.7

58.3 - 72.9

LINQCELL TFP800S

60 - 70

800

145.7

43.7 - 58.2

LINQCELL TFP

50 - 60

1,200

-

-

LINQCELL TPP250

30 - 40

250

-

-

LINQCELL TPP500

30 - 40

500

-

-

LINQCELL TPP

30 - 40

-

-

All the standard sheet sizes are 20 x 20cm

*Thickness tolerance is ±150um for all grades.

**The actual weight of the sheet will depend on the final porosity. This is the expected range.

Item

The company is the world’s best Stainless steel sintered felt supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Porosity (%)

 Thickness (um)*

Basis Weight (g)

Actual weight (g)**

LINQCELL GFP

-

-

-

LINQCELL GFP

-

-

-

LINQCELL GFP

-

590

-

Frequently Asked Questions

Learn More

Sintered Fiber Felt as a Porous Metal Material

Porous metal materials, characterized by their porous structures, are innovative engineering materials that offer impressive strength while being light. These materials are used across different industries, including aerospace, metallurgy, mechanics, petrochemicals, energy, pharmaceuticals, architecture, and transportation. Their unique properties make them suitable for specialized applications, such as in life support systems, energy storage, hydrogen generation, and filtration systems.

Porous metal materials can be categorized into three types:

• Metal Foams. Metal foams are lightweight cellular structures composed of a solid base metal with gas-filled pores, inspired by natural materials like wood, bones, and sea sponges. This design gives metal foams high strength-to-weight ratios and excellent energy absorption properties, making them ideal for use in diverse industries such as aerospace and automotive applications.
• Sintered Metal Powder. Sintered metal powder is a porous material produced by sintering, a process wherein the metallic powder is compressed and then heated at temperatures below its melting point. Sintering causes the particles to bond into a solid piece with small pores. Typically, sintered metal powders have a high solid volume fraction, ranging from 0.35 to 0.65; thus, this type of porous material is commonly used in applications where good mechanical strength is required.
• Sintered Fiber Felts. Advancements in fiber-pullout techniques have led to the development of sintered metal fiber felt, a non-woven, porous material made of long metallic fibers typically over 1.5 µm in diameter. These fiber felts are used in structural applications, such as the core of sandwich panels, as well as in functional applications like anodic gas diffusion layers, catalyst supports, and filtration nets.

Manufacturing Sintered Metal Powders vs. Sintered Metal Fiber Felts

Unlike metal foams, which are typically created through a foaming process that introduces gas into metallic melts, sintered metal powders and fiber felts are formed by sintering compacted powders or laminated fibers, respectively. 

Reference: Samal, Prasan K. Newkirk, Joseph W.. (). ASM Handbook, Volume 07 - Powder Metallurgy () - 34.2 Improved Mechanical Properties.(pp. 332). ASM International.

Sintering Mechanism in Metal Powders

The different sintering stages show how loose metal powders transform into a solid object:

In the final stage of sintering, interconnected open pores close and turn into isolated closed pores. As this happens, grain growth occurs, which slows down the surface and bulk diffusion processes. Consequently, this stage becomes the slowest, as densification increases from 95% to 99%.

(SD: Surface Diffusion, VD: Vacancy Diffusion, GB: Grain Boundary Diffusion)

Sintering Mechanism in Metal Fiber Felts

Throughout the sintering process of fiber felts, several transformations occur, such as the development of necks between fibers, the enlargement of grains within fibers, and changes  in porosity. Similar to powder sintering, sintering of fiber metal felts involves six modes of material transport. Three of these modes lead to sintering without densification: vapor transport, surface diffusion, and lattice diffusion from the surface. Conversely, the other three modes lead to densification: boundary diffusion, lattice diffusion from the grain boundary, and lattice diffusion from dislocation.

To predict the sintering conditions necessary to achieve desired properties, sintering diagrams have been developed for different powders and wires.  Originally, these diagrams were based on simple models, like the two-sphere model, which worked well for powders and wires. However, fiber felts, with their complex geometry, require a different approach. 

Unlike in powders, where sintering occurs between particles bonded by van der Waals forces, sintering in fiber felts takes place in the joints between adjacent fibers at random angles. During the pressing or shaping of fibers, sintering joints primarily develop at points where fibers make contact. Under pressure, fibers interlock, forming many contact areas. These contact regions can be categorized as either fiber-to-fiber contact joints or fiber-to-fiber mechanical meshing. 

During sintering, material migrates in fiber-to-fiber contact joints or mechanical meshing to reduce surface energy. Initially, sintering begins on microstructures' surfaces, forming contact points between fibers, which then strengthen. This process continues across the fiber network, forming a mesh-like structure. In comparison to sintering powders, sintering metal fiber felts undergo less densification. This is because surface processes, grain growth, and neck growth mechanisms dominate over densification processes like grain boundary diffusion.

Contact Regions in Sintered Fiber Felts: Fiber-to-fiber (a) contact joints and (b) mechanical meshing

(Image Source: Tang, Y. et al. () ‘An Innovative Fabrication Process of Porous Metal Fiber Sintered Felts with Three-Dimensional Reticulated Structure’, Materials and Manufacturing Processes, 25(7), pp. 565–571.)

Difference between Sintered Metal Powder and Sintered Metal Fiber Felt

Compared to sintered metal powder, sintered metal fiber felts are less dense, resulting in higher porosity and permeability. Sintered metal powders typically have porosities lower than 50%, whereas sintered metal fibers can achieve porosities higher than 50%. For instance, sintered titanium fiber felts can have porosities as high as 98%, with pore sizes smaller than 10 µm. Additionally, sintered metal fiber felts exhibit a three-dimensional reticulated structure. This structure not only provides well-defined conductive paths but also offers controlled electrical conductivity-temperature characteristics. The high porosity and decreased electrical resistivity due to the rupture of joint fiber contacts after sintering make sintered metal Fiber Felt an excellent material for applications such as water electrolyzers and fuel cells.

Scanning Electron Microscopy Images of Sintered Titanium (Left) Powder and (Right) Fiber Felt 

(Image Source: Omrani, Reza & Shabani, Bahman. (). Gas Diffusion Layers in Fuel Cells and Electrolysers: A Novel Semi-Empirical Model to Predict Electrical Conductivity of Sintered Metal Fibres. Energies. 12. 855.)

Sintered Titanium Fiber Felts

Titanium fiber papers represent a specialized category of materials known for their unique properties and applications in various industries. These papers are composed of titanium fibers intricately woven together to form a porous and conductive structure. With their exceptional characteristics, titanium fiber papers find utility in diverse fields, ranging from electrochemical systems to filtration and aerospace applications.

Titanium fiber papers serve as versatile components in electrochemical systems, such as proton exchange membrane (PEM) electrolyzers and solid oxide electrolyzers. They function as critical elements in these devices, playing roles as gas diffusion layers, current collectors, and support structures. Their high electrical conductivity and corrosion resistance ensure efficient electron and ion transport, while the porous structure allows for effective gas diffusion, aiding in reactant distribution and facilitating electrolyte permeation.

Beyond electrochemical applications, titanium fiber papers find use in filtration processes, where their porous nature enables effective separation of particles and contaminants from fluids. They are often employed as filter media in industries such as pharmaceuticals, wastewater treatment, and air purification. Additionally, titanium fiber papers have gained traction in the aerospace sector for their lightweight yet strong characteristics, making them suitable for applications such as sound absorption, thermal management, and composite reinforcement.

Titanium fiber paper manufacturing process and properties

Titanium fiber paper is produced from titanium fibers through a laying process that involves lamination and lapping. The laminated titanium fibers are then sintered at high temperature, thereby creating a strong and porous three-dimensional fiber network. This three-dimensional structure endows titanium fiber papers with high surface area-to-volume ratio, high porosity, and high permeability. On top of these properties, titanium fiber papers are also known to be electrically conductive, workable (i.e., fiber papers can be rolled and processed), and highly resistant to corrosion and thermal stress.

Titanium fiber felt applications

Titanium fiber papers are used in a wide array of applications including aerospace, medical, military, and filtration. Recently, they have been employed as flow field and anodic distributors in fuel cell and electrolysis stacks.

Titanium fiber paper vs. carbon fiber paper

At the cathode side, carbon paper is the predominantly used porous transport layer. On the other hand, at the oxygen (anode) side of fuel cells, the environment is much more corrosive because of usage of pure oxygen and application of potentials as high as 2 V. The highly oxidative environment at the anode corrodes the carbon-based LGDLs, thereby forming CO2 (Eqn. 1) and carbonate ions (Eqn. 2) in acidic and basic media, respectively. Carbon corrosion drastically reduces the the activity and stability of the anode during galvanic or electrolytic operations. For these reasons, metal-based PTLs, specifically titanium fiber papers, are used at the anode of fuel cells and water electrolyzers. 

Carbon Fiber Paper

Titanium Fiber Paper

Titanium fiber paper as anode LGDLs in fuel cells and electrolyzers

Introduction

Metal fiber felt is an innovative material widely used in various filtration applications. It possesses exceptional properties, including high porosity, excellent permeability, and resistance to high temperatures and corrosion.

Metal Fiber Felt

This article explores the different types of metal fiber felt, their unique benefits, and the wide array of applications ranging from aerospace to chemical processing. Hope that you can have a better understanding.

Learning about Metal Fiber Felt

Metal Fiber Felt is an advanced filtration material crafted from sintered metal fibers. It offers a unique combination of durability, precision, and efficiency in filtration applications. Unlike traditional woven or non-woven filtration materials, metal fiber felt comes with three-dimensional porosity and high surface area. These features allow for high filtration efficiency and excellent permeability.

This innovative material is produced by laying down fine metal fibers in a random web-like pattern. Thereafter, the high-temperature sintering process bonds the fibers at their contact points and creates a stable and robust structure capable of withstanding harsh environmental conditions.

Metal Fiber Felt’s versatility is further enhanced by the availability of different metals, such as stainless steel, nickel, titanium, and aluminum. Each of them stands out for specific properties tailored to particular applications. With its superior filtration capabilities, metal fiber felt plays a crucial role in improving product purity, protecting critical equipment, and ensuring the safety and efficiency of industrial processes.

Types of Metal Fiber Felt

You can classify metal fiber felt based on the metal type used in its production. Each type has its unique properties tailored to specific applications.

--Stainless Steel Fiber Felt

Stainless steel fiber felt is the most common type. It is prized for its resistance to oxidation and corrosion. It is ideal for applications involving high temperatures and corrosive fluids.

Stainless Steel Fiber Sintered Felt

--Nickel Fiber Felt

Nickel fiber felt is notable for its excellent thermal and electrical conductivity, so it is suitable for electrochemical and high-temperature filtration applications.

--Titanium Fiber Felt

Titanium fiber felt stands out for its extraordinary resistance to corrosion, especially in seawater and chlorine environments. Therefore, it is perfect for the chemical processing and marine industries.

Titanium Fiber Felt

--Aluminum Fiber Felt

Aluminum fiber felt offers excellent thermal conductivity and is lighter than other metal fiber felts. It has been ideal for aerospace and automotive applications where weight is a critical factor.

Benefits of Metal Fiber Felt

Metal fiber felt offers several advantages over traditional filtration materials, including:

• High Filtration Efficiency

The three-dimensional structure of metal fiber felt provides a high surface area for filtration. Consequently, it can capture particles effectively while maintaining excellent flow rates.

• Durability and Strength

The sintering process used to manufacture metal fiber felt imparts high mechanical strength and durability, so the material to withstand harsh operational conditions without degradation.

• High-Temperature Resistance

Metal fiber felt can operate effectively in environments with temperatures ranging from cryogenic levels to above °C, depending on the metal used.

• Corrosion Resistance

With materials like stainless steel, titanium, and nickel, metal fiber felt offers superior resistance to corrosion. It extends the lifespan of filtration systems in aggressive chemical environments.

• Customizability

Metal fiber felt can be produced with varying thicknesses, porosities, and fiber diameters. SAM allows for customization to meet specific filtration requirements.

Applications: Metal Fiber Felt for Filtration

The unique properties of metal fiber felt make it suitable for a wide range of applications across various industries.

1.    Chemical Processing

In chemical processing, metal fiber felt plays a crucial role in filtration systems designed to separate liquids and gases. This application is vital for maintaining the purity of chemical substances and preventing any form of contamination during critical manufacturing processes.

The material has resistance to a wide range of chemicals. It can withstand aggressive substances without degrading, thus guaranteeing consistent performance and reliability.

2.    Aerospace

The aerospace sector demands materials that can perform under the most rigorous conditions. Metal fiber felt has become an ideal choice for this industry. It is extensively used in the filtration of hydraulic systems and fuel lines. It is crucial for the safe and efficient operation of aircraft.

The material can withstand extreme temperatures and pressures. Besides, its durability makes it an essential component in ensuring the reliability of aerospace systems.

3.    Automotive

In the automotive industry, this felt finds various applications. It serves as a highly efficient filter medium for engine oil, fuel, and air. Its use significantly contributes to the enhanced performance and extended lifespan of vehicle components.

By effectively removing contaminants, it ensures optimal engine efficiency and reduces the wear and tear on automotive parts. It leads to improved vehicle reliability and performance over time.

4.    Pharmaceutical

The pharmaceutical industry requires stringent standards for purity and cleanliness, so metal fiber felt has become a valuable asset in the filtration of gases and liquids. Its utilization is critical in creating sterile conditions for the production of pharmaceuticals, where even minor contamination can have significant implications.

The material comes with high filtration efficiency and resistance to contamination. It is an ideal choice for maintaining the strict hygiene standards necessary in pharmaceutical manufacturing.

5.    Water Treatment

In water treatment facilities, this felt is employed to remove contaminants from water. It plays a pivotal role in ensuring the availability of clean and safe water.

Its effectiveness in filtering out harmful substances and particles contributes significantly to public health and environmental protection. The material's durability and resistance to biofouling make it suitable for long-term use in water treatment processes, where reliability and efficiency are essential.

Conclusion

Metal Fiber Felt for Filtration stands out with efficiency across diverse industrial applications. Its impact is profound, ranging from enhancing vehicle performance to ensuring the purity of pharmaceuticals and providing clean water.

As technology advances and demands for high-performance filtration materials rise, its role in supporting and advancing these critical industries is set to grow even further.

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