Fabrication of Bulk (Fe,Cr)3Al/Al2O3 Intermetallic Matrix Nanocomposite Through Mechanical Alloying and Sintering

doi:10.1007/s40195-016-0465-3

Abstract

Abstract:

In the present study, (Fe,Cr)₃Al/20 vol% Al₂O₃ nanocomposite was prepared through mechanochemical reactions during ball milling and successfully bulked using a combination of cold isostatic press and sintering at 1400 °C for 1 h. Two processing approaches were utilized to produce (Fe,Cr)₃Al/Al₂O₃ nanocomposite: The first was milling of Fe, Cr, Al and Fe₂O₃, while the second one was milling of Fe, Cr, Al and Cr₂O₃, both in stoichiometric condition, to synthesize (Fe,Cr)₃Al/20 vol% Al₂O₃. Structural changes of powder particles during mechanical alloying were studied by X-ray diffraction. The microstructure and the morphology of powder particles and bulk samples were also studied by scanning electron microscopy and transmission electron microscopy. Microstructural analysis showed that mechanochemical reactions took place during milling, and nanometric Al₂O₃ was uniformly distributed in the matrix. The results also showed that the second approach required a considerably higher milling time to produce (Fe,Cr)₃Al/Al₂O₃ nanocomposite, as compared to the first one. For this reason, bulk samples were produced from the synthesized nanocomposite in the first approach. The microstructure of the sintered samples consisted of a network structure of (Fe,Cr)₃Al and Al₂O₃ phases with superior mechanical properties.

Key words: Iron aluminide, Mechanical alloying, Nanocomposite, Mechanochemical treatment

Sayyed Erfan Aghili,Mohammad Hossein Enayati,Fathallah Karimzadeh. Fabrication of Bulk (Fe,Cr)₃Al/Al₂O₃ Intermetallic Matrix Nanocomposite Through Mechanical Alloying and Sintering[J]. Acta Metallurgica Sinica (English Letters), 2016, 29(10): 911-919.

Figures/Tables 13

Fig. 1 Morphologies of the as-received powder particles: a Fe, b Cr, c Al, d Cr2O3, e Fe2O3

Fig. 2 XRD patterns of the Fe-Cr-Al-Fe2O3 powder mixture a, the magnified XRD peak around 2θ of 43°-46° b

Fig. 3 TEM micrographs and SAD pattern (inset) of the 60 h milled (Fe,Cr)3Al/Al2O3 nanocomposite produced through the MA of the Fe-Cr-Al-Fe2O3 powder mixture: a bright field image, b dark field image

Fig. 4 XRD patterns of the Fe-Cr-Al-Cr2O3 powder mixture during ball milling

Fig. 5 TEM micrographs and SAD pattern (inset) of the (Fe,Cr)3Al/Al2O3 nanocomposite produced through the MA of the Fe-Cr-Al-Cr2O3 powder mixture: a bright field image, b dark field image

Fig. 6 XRD patterns of the (Fe,Cr)3Al/Al2O3 nanocomposite produced through the reduction of Fe2O3a, Cr2O3b after annealing at 900 °C for 1 h

Fig. 7 a Morphology of (Fe,Cr)3Al/Al2O3 nanocomposite after 60 h MA, b typical examples of the cold isostatic pressed nanocomposite

Fig. 8 XRD patterns of the (Fe,Cr)3Al/Al2O3 nanocomposite before a, after b sintering at 1400 °C for 1 h

Fig. 9 Microstructures of the bulk (Fe,Cr)3Al/Al2O3 nanocomposite at two magnifications a, b, the EDS analysis of light gray and dark gray regions c, d

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Fabrication of Bulk (Fe,Cr)₃Al/Al₂O₃ Intermetallic Matrix Nanocomposite Through Mechanical Alloying and Sintering

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