When fabricating a metal powder filter with a double-layered pore structure, which includes a microporous layer, by coating flake-shaped powder using the Wet Powder Spray (WPS) process, it is crucial to ensure that the coating is applied parallel to the surface of the metal powder filter. Failure to do so can result in a non-uniform pore structure, leading to a rapid decline in particle filtration efficiency. Therefore, it is necessary to improve the alignment of the coated flake-shaped powder on the filter surface. In this study, a metal powder filter with a double-layered pore structure was fabricated by applying a flake-shaped metal powder coating to a tube-shaped SUS316L powder filter using the WPS process. In order to improve the flake-shaped powder orientation of coating layer, the impact of the rolling process was investigated. The characteristics of the pores were analyzed based on the powder size and the rolling time. The microstructure of the fabricated metal powder filter was observed using an optical microscope, surface roughness, variations in thickness, and air permeability were analysed.

Generally, when fabricating porous filters using metal powder, about 1 to 2 wt% of a binder is added to increase the formability of the metal powder. If the binder is not completely removed through a debinding and sintering process, however it can cause defects such as discoloration and the generation of fine particles. In this study, a study was conducted to fabricate a plate-type porous stainless steel powder filter with a different pore structure without the use of a biner. First, the metal powder is charged into a ceramic mold to form a plate-shaped powder filter, and then covered with a ceramic top plate. In order to observe the pore properties according to the pressure, the unpressurized specimen and the specimen pressurized with a pressure of 30 MPa were then sintered at 1050℃ for one hour in a high vacuum atmosphere furnace. The microstructure of the sintered plate-shaped powder filter was observed through an optical microscope and in order to analyze its pore properties as a filter, gas permeability and porosity were measured using a capillary flow porometer and Archimedes’ law.