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Abstract: In this work, the dependence of microstructure of Fe–Al–Si alloy on conditions of reactive sintering was studied. It was shown that heating rate strongly affects the structure of this alloy. The microstructure consisting of uniformly distributed Al2Fe3Si3 particles in Al2FeSi matrix can only be obtained in this material by rapid heating (over 300Kmin−1). Sufficient reactive sintering temperature to obtain Al2Fe3Si3–Al2FeSi two-phase structure is 750°C. Further increase of the reaction temperature reduces porosity but causes a growth of Al2Fe3Si3 particles. Reactive sintering process is completed during less than 10min in the investigated material. Temperatures over 1050°C produce material composed of FeSi, FeAl and Al2Fe3Si3 phases. However, strongly exothermal reaction of FeSi formation causes melting of the sample. [Copyright &y& Elsevier]

Only differential thermal analysis at low heating rates or mathematical modelling have been used to determine Fe–Al phase formation reactions up to this day. In this work, Self-propagating High-temperature Synthesis high-speed reaction was analysed during extremely high heating rates using scanning electron microscope with energy dispersive spectroscopy and X-ray diffraction in this work. Samples, whose chemical composition corresponded to FeAl phase, were sintered at heating rate of 300 °C/min, the highest heating rate applied so far. The course of heating was observed by optical pyrometer with sampling rate of 0.02 s. Pre-combustion peak (diffusion stage) was identified in the alloy prior steep combustion peak corresponding to SHS reaction itself. Accordingly to the temperature development, a FeAl phase formed initially allowing to react with aluminium and forming Fe 2 Al 5 phase. Furthermore, the later mentioned phase partially reacted with aluminium resulting in a presence of metastable FeAl 3 phase. Resulted microstructure was composed of only FeAl phase. This is completely reverse order of phase formation as was presented in previous studies focusing on lower heating rates where Fe 2 Al 5 formed first during diffusion stage followed by the formation of FeAl at SHS reaction. [ABSTRACT FROM AUTHOR]