Characterization of mechanically alloyed FeAlSi intermetallic powders

Powder metallurgy is very promising material production technology which allows to prepare the alloys that could hardly be manufactured by other processing route. Basic prerequisite to obtain the product of desired properties is the high quality of initial primary commodities, i.e. powders in the case of powder metallurgy. One of the available methods of powder preparation is so called mechanical alloying which starts from blended powder mixtures and allows production of homogeneous materials by severe deformation in a high-energy ball charge. This technology is especially suitable for brittle materials such as intermetallic alloys being developed for high-temperature and corrosive environments applications [1]. Please click Additional Files below to see the full abstract

FRACTURE BEHAVIOR OF FeAlSi INTERMETALLICS

The study is devoted to the intermetallic alloy FeAl20Si20 (wt.%) with the potential applications in high temperature aggressive environments. The samples of the same chemical composition were prepared by spark plasma sintering from the different mechanically alloyed powders (pure elements and pre-alloyed powders). Differences in mechanical properties were characterized. Whereas no significant differences were found in hardness and Young´s modulus, fracture resistance was higher for the samples from pre-alloyed powders in which Palmqvist and lateral cracks were observed (contrary to the sample made of pure elements where only Palmqvist cracks were identified)

Formation of Ni-Ti intermetallics during reactive sintering at 800-900 °C

In this work the formation of intermetallics in the Ni-Ti system by reactive sintering at 800-900 degrees C was studied. The mechanism and kinetics of the reactions, which led to Ni-Ti phases, were determined by thermal analysis, in-situ XRD and the application of an experimental model consisting of nickel-plated titanium. It was found that the formation of Ni-Ti phases below the transformation temperature of titanium is controlled by diffusion. Above this temperature, the reactions switch to the rapid Self-propagating High-temperature Synthesis (SHS) mode

Influence of the Al Content on the Properties of Mechanically Alloyed CoCrFeNiMnXAl20−X High-Entropy Alloys

The equiatomic CoCrFeNiMn alloy prepared by mechanical alloying and spark plasma sintering underwent partial substitution of Mn by Al (5, 10 and 15 at.%) to determine its influence on mechanical properties and thermal stability. It was discovered that the higher the Al content, the higher the volume fraction of the hard phase with primitive cubic (PC) crystallographic lattice, which increases the hardness and strength of the alloys. The most promising mechanical properties have been achieved in the CoCrFeNiMn5Al15 alloy reaching the compressive yield strength (CYS) of 2135 ± 21 MPa and the ultimate compressive strength (UCS) of 2496 ± 21 MPa. All the prepared alloys showed good thermal stability as they maintained or only slightly reduced their initial hardness during the 100 h annealing at 800 °C. Furthermore, the higher the Al content, the higher the resistance against high-temperature oxidation. The oxidic layer changed its composition from Mn-oxides (CoCrFeNiMn15Al15 alloy) to Al-based oxides with exceptional protective properties

Effect of Nickel and Titanium on Properties of Fe-Al-Si Alloy Prepared by Mechanical Alloying and Spark Plasma Sintering

This paper describes the structure and properties of an innovative Fe-Al-Si alloy with a reduced amount of silicon (5 wt. %) in order to avoid excessive brittleness. The alloy was produced by a combination of mechanical alloying and spark plasma sintering. Nickel and titanium were independently tested as the alloying elements for this alloy. It was found that wear resistance, which reached values comparable with tool steels, could be further improved by the addition of nickel. Nickel also improved the high-temperature oxidation behavior, because it lowers the liability of the oxide layers to spallation. Both nickel and titanium increased the hardness of the alloy. Titanium negatively influenced oxidation behavior and wear resistance because of the presence of titanium dioxide in the oxide layer and the brittle silicides that caused chipping wear, respectively

Properties Comparison of Ti-Al-Si Alloys Produced by Various Metallurgy Methods

Melting metallurgy is still the most frequently used and simplest method for the processing of metallic materials. Some of the materials (especially intermetallics) are very difficult to prepare by this method due to the high melting points, poor fluidity, or formation of cracks and pores after casting. This article describes the processing of Ti-Al-Si alloys by arc melting, and shows the microstructure, phase composition, hardness, fracture toughness, and compression tests of these alloys. These results are compared with the same alloys prepared by powder metallurgy by the means of a combination of mechanical alloying and spark plasma sintering. Ti-Al-Si alloys processed by melting metallurgy are characterized by a very coarse structure with central porosity. The phase composition is formed by titanium aluminides and titanium silicides, which are full of cracks. Ti-Al-Si alloys processed by the powder metallurgy route have a relatively homogeneous fine-grained structure with higher hardness. However, these alloys are very brittle. On the other hand, the fracture toughness of arc-melted samples is immeasurable using Palmqvist’s method because the crack is stopped by a large area of titanium aluminide matrix

Indentation Size Effect in CoCrFeMnNi HEA Prepared by Various Techniques

High entropy alloys (HEAs) are materials of great application potential and which have been extensively studied during the last two decades. As the number of possible element combinations is enormous, model materials representing certain groups of HEAs are used for the description of microstructure, properties, and deformation mechanisms. In this study, the microstructure and mechanical properties of the so-called Cantor alloy composed of Co, Cr, Fe, Mn, and Ni in equiatomic ratios prepared by various techniques (casting, melt-spinning, spark plasma sintering) were examined. The research focused on the indentation measurements, namely, the indentation size effect describing the evolution of the hardness with penetration depth. It was found that the standard Nix–Gao model can be used for this type of alloy at higher penetration depths and its parameters correlate well with microstructural observations. The Nix–Gao model deviates from the measured data at the submicrometer range and the applied modification affords additional information on the deformation mechanism

Microstructure and Mechanical Properties of Ti-25Nb-4Ta-8Sn Alloy Prepared by Spark Plasma Sintering

As the commercially most-used Ti-6Al-4V alloy has a different modulus of elasticity compared to the modulus of elasticity of bone and contains allergenic elements, β-Ti alloy could be a suitable substitution in orthopedics. The spark plasma sintering (SPS) method is feasible for the preparation of materials, with very low porosity and fine-grained structure, leading to higher mechanical properties. In this study, we prepared quaternary Ti-25Nb-4Ta-8Sn alloy using the spark plasma sintering method. The material was also heat-treated in order to homogenize the structure and compare the microstructure and properties in as-sintered and annealed states. The SPS sample had a modulus of elasticity of about 63 ± 1 GPa, which, after annealing, increased to the value of 73 ± 1 GPa. The tensile yield strength (TYS) of the SPS sample was 730 ± 52 MPa, ultimate tensile strength (UTS) 764 ± 10 MPa, and ductility 22 ± 9%. Annealed samples reached higher values of TYS and UTS (831 ± 60 MPa and 954 ± 48 MPa), but the ductility decreased to the value of 3 ± 1%. The obtained results are discussed considering the observed microstructure of the alloy

Properties of FeAlSi-X-Y Alloys (X,Y=Ni, Mo) Prepared by Mechanical Alloying and Spark Plasma Sintering

Short-term mechanical alloying and compaction by spark plasma sintering was used for the production of FeAl20Si20Mo20-XNiX (X corresponds to 5–15 wt %) alloy, which showed an ultrafine-grained microstructure with dimensions of phases around 200 nm or smaller. It was found that the addition of Mo and Ni to the FeAl20Si20 alloy results in the formation of the AlMoSi phase compared to the three-phase FeAl20Si20 alloy, which initially contained FeSi, Fe3Si, and Fe3Al2Si3 phases. All the investigated alloys increased their hardness, reaching up to 1401 HV 1 for the FeAl20Si20Mo5Ni15 alloy, which contained in total 58.5% of the FeSi and Fe3Al2Si3 phases. As a result, all the prepared alloys showed one order magnitude lower wear rates ranging from 3.14 to 5.97·10−6 mm3·N−1·m−1 as well as significantly lower friction coefficients compared to two reference tool steels. The alloys achieved high compressive strengths (up to 2200 MPa); however, they also exhibited high brittleness even after long-term annealing, which reduced the strengths of all the alloys below approximately 1600 MPa. Furthermore, the alloys were showing ductile behavior when compressively tested at elevated temperature of 800 °C. The oxidation resistance of the alloys was superior due to the formation of a compact Al2O3 protective layer that did not delaminate

Synthesis of Intermetallics in Fe-Al-Si System by Mechanical Alloying

Fe-Al-Si alloys have been recently developed in order to obtain excellent high-temperature mechanical properties and oxidation resistance. However, their production by conventional metallurgical processes is problematic. In this work, an innovative processing method, based on ultra-high energy mechanical alloying, has been tested for the preparation of these alloys. It has been found that the powders of low-silicon alloys (up to 10 wt. %) consist of FeAl phase supersaturated by Si after mechanical alloying. Fe2Al5 phase forms as a transient phase at the initial stage of mechanical alloying. The alloy containing 20 wt. % of Si and 20 wt. % of Al is composed mostly of iron silicides (Fe3Si and FeSi) and FeAl ordered phase. Thermal stability of the mechanically alloyed powders was studied in order to predict the sintering behavior during possible compaction via spark plasma sintering or other methods. The formation of Fe2Al5 phase and Fe3Si or Fe2Al3Si3 phases was detected after annealing depending on the alloy composition. It implies that the powders after mechanical alloying are in a metastable state; therefore, chemical reactions can be expected in the powders during sintering