With the increasing demand for high-temperature gas filtration, porous intermetallic compounds have attracted much attention. In this study, high porosity CoAl with 3D microstructures was prepared using the thermal explosion. The link between the pore structure , mechanical and oxidation resistance of the product was established using 3D-XRM. Moreover, an oxidation corrosion test was conducted in fluid and static air at 700–900 °C for up to 120 h. During the rapid growth stage, the mass gain was dominated by the inward diffusion of O, while during the slow growth stage, it was dominated by the outward diffusion of Al.
The micro/nano-scale porous CoAl intermetallic compound (IMC) was fabricated using thermal explosion (TE) method combining space holder. By investigating the samples with 3D-XRM, the link between the structure of the pores and the permeability performance of the product was established. Oxidative corrosion tests were performed in static air at 600 °C for 120 h. There are two stages of corrosion: in the first four hours of the oxidation experiment, the reaction of O was mainly dominated; after that, the diffusion of Al was dominated. This structure-function integrated porous CoAl will create a new pathway for industrial-scale high-temperature oxygenated gas filtration works.