Tungsten Strongly Inhibits Sintering of Porous Iron During High-Temperature Redox Cycling.

Freeze-cast Fe-25 W (at%) lamellar foams show excellent resistance to degradation at 800 °C during steam-hydrogen redox cycling between the metallic and oxide states, with fast reaction kinetics maintained up to at least 100 redox cycles with full Fe utilization. This very high stability stems from the sintering inhibition of W combined with the freeze-cast architecture and the chemical vapor transport (CVT) mechanism of reduction. These three factors create a hierarchical porosity in the foam, consisting of i) macroscopic elongated channels, ii) micro-scale sintering inhibition pores, and iii) submicron CVT pores. Microstructural characterization via SEM and EDS is combined with in situ XRD to fully explore the phase evolution and microstructural impact of W on Fe during redox cycling. Comparison with tapped Fe-25 W (at%) powder beds reveals that the freeze-cast channels and lamellae are not critical to the performance of the material.