Microstructure and tensile properties of Fe₃Al produced by combustion synthesis/hot isostatic pressing

Abstract

Combustion synthesis was carried out in a hot isostatic press (HIP) in order to prepare near-theoretical density Fe₃Al and Fe₃Al + Cr alloys from elemental powder mixtures. The microstructures and room-temperature tensile properties of these materials were studied in the as-synthesized condition and after heat treatment. As-synthesized materials exhibit a fine, equiaxed grain structure with grain sizes typically less than 10 μm. Yield and ultimate tensile strengths were found to be significantly higher than what has been reported for conventionally processed materials having similar composition. Although lower ductility was generally observed, elongations exceeding 5 pct were obtained in heat-treated Cr-containing alloys. Fracture occurred predominantly by transgranular cleavage. The strengthening of these materials is attributed to the fine grain size resulting from combustion synthesis/HIP processing. Transmission electron microscopy (TEM) revealed the presence of two distinct populations of aluminum oxide particles in the material. Nanometer-sized oxides exist within grains that likely formed at prior iron particle boundaries, and a high density of larger oxides exist along grain boundaries that probably originated from surface oxides on the aluminum powder. The presence of the grain boundary oxides was qualitatively observed to provide resistance to grain growth.