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Composites consisting of iron aluminide and iron silicide phases were studied in this work. Powders of iron aluminide and iron silicide were prepared by mechanical alloying separately. Subsequently, they were blended in three different proportions and sintered by the SPS method under various conditions. After sintering, the composites are composed of FeAl and amounts of other silicides (Fe5Si3 and Fe3Si). Ternary Fe–Al–Si phases were not determined, even though their presence was predicted by DFT calculations. This disagreement was explained by steric factors, i.e., by differences in the space lattice of the present phases. Hardness and tribological properties were measured on composites with various weight ratios of iron aluminide and iron silicide. The results show that sintered silicides with the matrix composed of iron aluminide reach comparable hardness to tool steels. The composites with higher mass ratios of iron aluminide than silicide have higher hardness and better tribological properties. [ABSTRACT FROM AUTHOR]

This work presents the possibilities of producing a substitute for a commercial matrix material for sintered metal–diamond tools which is characterized by increased tribological properties required in machining natural stones and concrete. In this study, the improvement in wear behavior of sintered pre-alloyed matrix caused by a thermal treatment was investigated. Several mixtures made of commercially available powders were homogenized by ball milling and consolidated at 900 °C using the spark plasma sintering (SPS) method. During cooling down, the specimens were subjected to isothermal holding at 350 or 250 °C for 1 h. After consolidation, all specimens were tested for density and hardness, whereas selected specimens were characterized by scanning electron microscopy (SEM) and flexural strength tests. The specimens made of BDCM50 powder (a mixture of the base and pre-alloyed powders in 50:50 proportion) shows excellent properties including σ0.2 = 1045 MPa in the three-point bending test and HV10 ≈ 380. Resistance to abrasive wear evaluated in both three-body and two-body conditions in the MWT abrasion test was estimated at A i 3 = 18.1 ± 3.9 μm/20 m and   A i 2 = 95.9 ± 11.8 μm/20 m, respectively. A series of diamond-impregnated specimens (segments) was also produced and tested for wear rate on abrasive concrete. The potential graphitization of the diamond grits was investigated using Raman spectroscopy and X-ray diffraction. As a reference, both the base Fe-Mn-Cu-Sn-C and commercially available Co+20%WC alloy were used to compare selected properties of the investigated materials. It has been proved that heat-treated specimens made of the base mixture modified with pre-alloyed powders are characterized by increased hardness and resistance to abrasive wear. The BDCM50 matrix has a negligible effect on diamond graphitization and shows excellent field performance, which makes it a good potential substitute for replacing Co+20%WC in sintered diamond-impregnated tools. [ABSTRACT FROM AUTHOR]

Niobium is recently considered one of the potential alloying elements for tool steels due to the formation of hard and stable carbides of MC type. Its use is limited by the fact that these carbides tend to coarsen during conventional melting metallurgy processing. This work explores the potential of additive manufacturing for processing Nb-alloyed tool steel with a high content of carbon. Directed energy deposition was used as the processing method. It was found that this method allowed us to obtain a microstructure very similar to that obtained after the use of consolidation via spark plasma sintering when subsequent heat treatment by soft annealing, austenitizing, oil quenching and triple tempering for secondary hardness was applied. Moreover, the soft annealing process could be skipped without affecting the structure and properties when machining would not be required. The hardness of the steel was even higher after additive manufacturing was used (approx. 800–830 HV 30) than after spark plasma sintering (approx. 720–750 HV 30). The wear resistance of the materials processed by both routes was almost comparable, reaching 5–7 × 10−6 mm3N−1m−1 depending on the heat treatment. [ABSTRACT FROM AUTHOR]

Commercially supplied inoculation wires have a guaranteed chemical composition but not the size and distribution of individual phases, which are very important for nucleation. Therefore, two commercial alloys used for the inoculation of Al-Si alloys (AlTi3B1 and AlTi5B1) are investigated in this paper. The emphasis is placed on their structural analysis and the size and distribution of individual intermetallic phases. Furthermore, the grain refinement effect will be tested by adding these alloys to the AlSi7Mg0.3 alloy and testing the optimal amount of added inoculation wires. The results showed that the size and distribution of the individual phases in AlTi3B1 and AlTi5B1 meet the requirements for the successful inoculation of aluminum alloys, the intermetallic phases based on the TiAl3 phase are fine enough, and there is no agglomeration that would reduce the number of nuclei. This assumption was confirmed by adding these inoculants to the AlSi7Mg0.3 alloy, and it was found that the most ideal amount of inoculants added is 0.01 wt % when the structure was refined by approximately 32%. [ABSTRACT FROM AUTHOR]

Aluminothermic reduction without the separation of individual metals is currently considered as a possible method for processing ferromanganese sea nodules and creating new alloys. In this study, the product of their reduction—a manganese-based polymetallic mixture—was added to pure aluminum, as a mixture of alloying elements in their natural ratios. After extrusion, two new aluminum alloys with a total percentage of metallic additives ranging from 1 to 6 percent were prepared. The possibilities of the precipitation strengthening of these aluminum alloys, especially those containing Mn, Fe, Si, Ni, and Cu, were investigated under a wide range of heat treatment conditions. After each tested combination of annealing and artificial aging temperatures, the phase composition and the microstructure changes were recorded by X-ray diffraction, optical, and scanning electron microscopy with EDS analysis. Under none of the tested heat treatment conditions is a significant hardening effect observed, even though the precipitate phases are observed by TEM. However, the changes in the morphology of the present intermetallic phases caused by the heat treatment are revealed, which highlights the further possible development of these multicomponent alloys. [ABSTRACT FROM AUTHOR]

This work investigated the possibility of the direct preparation of aluminum alloys by aluminothermic reduction of deep-sea nodules with a high excess of aluminum. The process was found to be unable to obtain aluminum alloy, but an aluminum-rich manganese-based alloy was obtained instead, being composed of intermetallics. The alloy was characterized in the as-reduced state, as well as after crushing and sintering in the temperature range of 800–950 °C. The sample sintered at 900 °C was also heat-treated by annealing at 800 °C for 3 h and rapidly cooled. It was observed that with the increasing sintering temperature, the original matrix phase Al11Mn14 was transformed into a duplex matrix with a structure corresponding to Al11Mn14 and Al4Cu9, and this mixture was further transformed to the matrix with the structure corresponding to Al4Cu9. Furthermore, the mechanical properties and wear resistance of the samples were described. The highest microhardness was reached in the sample, which was annealed after sintering. Sintered samples reached a lower wear rate because of the fragmentation of brittle intermetallics during crushing. [ABSTRACT FROM AUTHOR]

The Heat Treatment of Metallic Materials in Modern Industry is a Special Issue of the journal I Materials i , which aims to publish original full-length articles and review papers on basic and applied research centered around the given topic, and thereby make the understanding of the metallurgical background of the contemporary state of heat treatment techniques used in the industrial branches in the 21st century. Finally, the papers on laser- or electron-beam surface treatments as well as the physical vapor deposition of thin films are of interest to the Editors of this Special Issue. The papers which explore the research and development works on bulk heat and cryogenic treatment of steel, aluminium, titanium, magnesium, or copper alloys are particularly welcome. [Extracted from the article]

In this work, the structure and mechanical properties of innovative Al-Cu-Fe based alloys were studied. We focused on preparation and characterization of rapidly solidified and hot extruded Al-Cu-Fe, Al-Cu-Fe-Ni and Al-Cu-Fe-Cr alloys. The content of transition metals affects mechanical properties and structure. For this reason, microstructure, phase composition, hardness and thermal stability have been investigated in this study. The results showed exceptional thermal stability of these alloys and very good values of mechanical properties. Alloying by chromium ensured the highest thermal stability, while nickel addition refined the structure of the consolidated alloy. High thermal stability of all tested alloys was described in context with the transformation of the quasicrystalline phases to other types of intermetallics. [ABSTRACT FROM AUTHOR]

The microstructure, phase composition, and microhardness of both gas-atomized and mechanically milled powders of the Al7075 + 1 wt % Zr alloy were investigated. The gas-atomized powder exhibited a cellular microstructure (grain size of a few µm) with layers of intermetallic phases along the cell boundaries. Mechanical milling (400 revolutions per minute (RPM)/8 h) resulted in a grain size reduction to the nanocrystalline range (20 to 100 nm) along with the dissolution of the intermetallic phases. Milling led to an increase in the powder's microhardness from 97 to 343 HV. Compacts prepared by spark plasma sintering (SPS) exhibited negligible porosity. The grain size of the originally gas-atomized material was retained, but the continuous layers of intermetallic phases were replaced by individual particles. Recrystallization led to a grain size increase to 365 nm in the SPS compact prepared from the originally milled powder. Small precipitates of the Al3Zr phase were observed in the SPS compacts, and they are believed to be responsible for the retainment of the sub-microcrystalline microstructure during SPS. A more intensive precipitation in this SPS compact can be attributed to a faster diffusion due to a high density of dislocations and grain boundaries in the milled powder. [ABSTRACT FROM AUTHOR]

Ti–Al–Si alloys are prospective material for high-temperature applications. Due to low density, good mechanical properties, and oxidation resistance, these intermetallic alloys can be used in the aerospace and automobile industries. Ti–Al–Si alloys were prepared by powder metallurgy using reactive sintering, milling, and spark plasma sintering. One of the novel SPS techniques is high-pressure spark plasma sintering (HP SPS), which was tested in this work and applied to a Ti–10Al–20Si intermetallic alloy using a pressure of 6 GPa and temperatures ranging from 1318 K (1045 °C) to 1597 K (1324 °C). The low-porosity consolidated samples consist of Ti5Si3 silicides in an aluminide (TiAl) matrix. The hardness varied between 720 and 892 HV 5. [ABSTRACT FROM AUTHOR]

Deep-sea manganese nodules are polymetallic oxidic ores that can be found on a seabed. Aluminothermic reduction is one of the possibilities of manganese nodules processing. This process obtains the polymetallic alloy with a high content of Mn and a varying content of Al, depending on the ratio between aluminum and nodules. The corrosion behaviors of three experimental Mn-based alloys produced by aluminothermic reduction with a content of Mn > 50 wt % were studied. The electrochemical testing in potable water and model seawater was used to explain the corrosion mechanism of Mn-based alloys. The results showed that the corrosion rate of experimental Mn-based alloy decreases with the increase in aluminum content in both potable water and model seawater. It was observed that the uniform corrosion of experimental Mn-based alloys is changed with an increase in aluminum content in alloy to localized corrosion, which was caused by microcells in an environment of model seawater. In contrast, the formation of a semi-protective layer of corrosion products was observed on the surface of Mn-based alloys with a higher content of aluminum in potable water. Moreover, the pitting corrosion of tested Mn-based alloys was observed neither in potable water nor in model seawater. [ABSTRACT FROM AUTHOR]

Novel high-entropy (multi-principal elements) alloy based on Fe-Al-Si-Ni-Ti in equimolar proportions has been developed. The alloy powder obtained by mechanical alloying is composed of orthorhombic FeTiSi phase with the admixture of B2 FeAl. During spark plasma sintering of this powder, the FeSi phase is formed and the amount of FeAl phase increases at the expense of the FeTiSi phase. The material is characterized by a high compressive strength (approx. 1500 MPa) at room temperature, being brittle. At 800 °C, the alloy is plastically deformable, having a yield strength of 459 MPa. The wear resistance of the material is very good, comparable to the tool steel. During the wear test, the spallation of the FeSi particles from the wear track was observed locally. [ABSTRACT FROM AUTHOR]

A new powder production method has been developed to speed up the search for novel alloys for additive manufacturing. The technique involves an ultrasonically agitated cold crucible installed at the top of a 20 kHz ultrasonic sonotrode. The material is melted with an electric arc and undergoes pulverization with standing wave vibrations. Several different alloys in various forms, including noble and metallic glass alloys, were chosen to test the process. The atomized particles showed exceptional sphericity, while powder output suitable for additive manufacturing reached up to 60%. The AMZ4 metallic glass powder remained amorphous below the 50 μm fraction, while tungsten addition led to crystallization in each fraction. Minor contamination and high Mn and Zn evaporation, especially in the finest particles, was observed in atomized powders. The innovative ultrasonic atomization method appears as a promising tool for material scientists to develop powders with tailored chemical composition, size and structure. [ABSTRACT FROM AUTHOR]

Electric field-assisted sintering has ubiquitous merits over conventional sintering technology for the fabrication of difficult-to-deform materials. To investigate the effect of sintering pressure and temperature on the densification of Inconel 718 superalloy, a numerical simulation model was established based on the Fleck-Kuhn-McMeeking (FKM) and Gurson-Tvergaard-Needleman (GTN) models, which covers a wide range of porosity. At a sintering pressure below 50 MPa or a sintering temperature below 950 °C, the average porosity of the sintered superalloy is over 0.17 with low densification. Under a pressure above 110 MPa and a temperature above 1250 °C, the sintered superalloy quickly completes densification and enters the plastic yield stage, making it difficult to control the sintering process. When the pressure is above 70 MPa while the temperature exceeds 1150 °C, the average porosity is 0.11, with little fall when the pressure or temperature rises. The experimental results indicated that the relative density of the sintered superalloy under 70 MPa and 1150 °C is 94.46%, and the proportion of the grain size below 10 μm is 73%. In addition, the yield strength of the sintered sample is 512 MPa, the compressive strength comes to 1260 MPa when the strain is over 0.8, and the microhardness is 395 Hv, demonstrating a better mechanical property than the conventional superalloy. [ABSTRACT FROM AUTHOR]

This article describes issues related to the machining of parts made of sintered nickel-cobalt alloy. Longitudinal turning with a CBN (cubic boron nitride) tool was analyzed. The results of experiments showed the influence of cutting parameters in the field of finishing machining on the values of cutting forces and specific cutting force, taking into account the wear of the cutting edge. Measurements and analysis of the topography and roughness parameters of the machined surface, as well as the cutting tool wear, were presented. The microscopic examination showed that the average grain size of the sintered nickel-cobalt alloy was 3.22 ± 0.1 (μm). The presence of the hardening state variability of the material during machining, as well as the value of the cutting force fluctuation as a function of the tool wear VB, were stated. The specific cutting force values increased to a small degree for the tool wear in the range of VB = 0–0.2 mm, and reached similar values in the range kc = 5500–7500 N/mm2. The specific cutting force values increased significantly for wear VB > 0.2 mm and were characterized by a large variability. The occurring phenomena were analyzed and several explanations were proposed. A recommendation was developed for the machining of parts made of sintered nickel-cobalt alloy. The Taguchi method was used in the experiment methodology. [ABSTRACT FROM AUTHOR]

This paper describes the effect of silicon on the manufacturing process, structure, phase composition, and selected properties of titanium aluminide alloys. The experimental generation of TiAl–Si alloys is composed of titanium aluminide (TiAl, Ti3Al or TiAl3) matrix reinforced by hard and heat-resistant titanium silicides (especially Ti5Si3). The alloys are characterized by wear resistance comparable with tool steels, high hardness, and very good resistance to oxidation at high temperatures (up to 1000 °C), but also low room-temperature ductility, as is typical also for other intermetallic materials. These alloys had been successfully prepared by the means of powder metallurgical routes and melting metallurgy methods. [ABSTRACT FROM AUTHOR]

The Critical Raw Materials (CRMs) list has been defined based on economic importance and supply risk by the European Commission. This review paper describes two issues regarding critical raw materials: the possibilities of their substitution in iron-based alloys and the use of iron-based alloys instead of other materials in order to save CRMs. This review covers strategies for saving chromium in stainless steel, substitution or lowering the amounts of carbide-forming elements (especially tungsten and vanadium) in tool steel and alternative iron-based CRM-free and low-CRM materials: austempered ductile cast iron, high-temperature alloys based on intermetallics of iron and sintered diamond tools with an iron-containing low-cobalt binder. [ABSTRACT FROM AUTHOR]

Intermetallic compounds based on Ti-Al- (Si) are attractive materials with good thermal stability and low density. However, the production of these materials is quite complicated. Partially modified conventional methods of melting metallurgy are most often used due to availability, possible high productivity, and relatively low production costs. Therefore, some technologies for the production of intermetallics based on Ti-Al are currently available, but with certain disadvantages, which are caused by poor casting properties or extreme reactivity of the melt with crucibles. Some shortcomings can be eliminated by modifying the melting technology, which contributes to increasing the cost of the process. The work deals with the preparation of Ti-Al-Si intermetallic compounds with different contents of aluminum and silicon, which were produced by centrifugal casting in an induction vacuum furnace Linn Supercast-Titan. This process could contribute to the commercial use of these alloys in the future. For this research, the TiAl15Si15(in wt.%) alloy was selected, which represents a balanced ratio of aluminides and silicides in its structure, and the TiAl35Si5 alloy, which due to the lower silicon content allows better melting conditions, especially with regard to the melting temperature. This alloy was also investigated after HIP ("Hot Isostatic Pressing") treatment. [ABSTRACT FROM AUTHOR]

A low-cost titanium alloy (Ti–5Al–2Fe–3Mo wt.%) was designed and fabricated by blended elemental powder metallurgy (BEPM) process. The high-temperature deformation behavior of the powder metallurgical Ti–5Al–2Fe–3Mo wt.% (PM-TiAlFeMo) alloy was investigated by hot compression tests at temperatures ranging from 700 to 1000 °C and strain rates ranging from 0.001 to 10 s−1. The flow curves were employed to develop the Arrhenius-type constitutive model in consideration of effects of deformation temperature, strain rate, and flow stress. The value of activation energy (Q) was determined as 413.25 kJ/mol. In order to describe the workability and predict the optimum hot processing parameters of the PM-TiAlFeMo alloy, the processing map has been established based on the true stress–true strain curves and power dissipation efficiency map. Moreover, microstructure observations match well with the analyses about deformation mechanisms, revealing that dynamic recovery and dynamic recrystallization are dominant softening mechanisms at relatively high temperatures. However, the kinking and breaking of microstructure prefer to occur at relatively low temperatures. [ABSTRACT FROM AUTHOR]

This paper brings an innovative processing route of manganese deep-sea nodules, which results in completely new grades of alloys. Deep-sea nodules were processed by aluminothermic method without the extraction of individual elements, producing complexly alloyed manganese-based "natural alloys". Three levels of the amount of aluminum were used for the aluminothermic reduction, and hence the alloys differ strongly in the amount of aluminum, which has a significant effect on their phase composition. The alloys have very high wear resistance, comparable with tool steel. The disadvantage of low-aluminum alloy is the susceptibility to local thermal cracking during friction, which occurs especially in the case of a dry sliding wear against the static partner with low thermal conductivity. [ABSTRACT FROM AUTHOR]

The 24CrNiMo alloy steel powder was used as experimental material. The microstructure and mechanical properties of as-deposited, quenched and tempered (QT) and stress-relief annealed (SR) specimens were analyzed. The X-ray diffraction (XRD) analysis showed that the specimens in the three states were mainly ferrite (α-Fe), in which the as-deposited samples had puny face-centered cubic (FCC) structure Fe (γ-Fe). The microstructure observation showed that the as-deposited specimens were made up of ferrite, granular bainite, a small amount of cementite and residual austenite. The tensile test results indicated that the tensile strength and yield strength of the as-deposited specimens were 1199 MPa and 1053 MPa respectively, and the elongation at break was 10.7%. The elongation of QT and SR specimens increased to 11.6% and 12.8%, respectively. The electron backscattered scattering detection (EBSD) analysis results showed that the small-angle grain boundary content of the as-deposited samples was 58%, and large-angle grain boundary content was 15%. After QT and SR, small-angle and large-angle grain boundaries were obtained than those in the as-deposited specimens. The high-temperature friction and wear properties and thermal fatigue performances of the QT and SR specimens were improved significantly. The QT specimens had the smallest wear and thermal fatigue crack lengths, excellent resistance to friction and wear performance and prevention of crack growth, with an ideal comprehensive properties. [ABSTRACT FROM AUTHOR]

Titanium and its alloys belong to the group of materials used in implantology due to their biocompatibility, outstanding corrosion resistance and good mechanical properties. However, the value of Young's modulus is too high in comparison with the human bone, which could result in the failure of implants. This problem can be overcome by creating pores in the materials, which, moreover, improves the osseointegration. Therefore, TiSi2 and TiSi2 with 20 wt.% of the pore-forming agent (PA) were prepared by reactive sintering and compared with pure titanium and titanium with the addition of various PA content in this study. For manufacturing implants (especially augmentation or spinal replacements), titanium with PA seemed to be more suitable than TiSi2 + 20 wt.% PA. In addition, titanium with 30 or 40 wt.% PA contained pores with a size allowing bone tissue ingrowth. Furthermore, Ti + 30 wt.% PA was more suitable material in terms of corrosion resistance; however, its Young's modulus was higher than that of the human bone while Ti + 40 wt.% PA had a Young's modulus close to the human bone. [ABSTRACT FROM AUTHOR]

Powder metallurgy is a group of advanced processes for the synthesis, processing, and shaping of various kinds of materials. Initially inspired by ceramics processing, the methodology comprising of the production of a powder and its transformation to a compact solid product has attracted great attention since the end of World War II. At present, there are many technologies for powder production (e.g., gas atomization of the melt, chemical reduction, milling, and mechanical alloying) and its consolidation (e.g., pressing and sintering, hot isostatic pressing, and spark plasma sintering). The most promising ones can achieve an ultra-fine or nano-grained structure of the powder, and preserve it during consolidation. Among these methods, mechanical alloying and spark plasma sintering play a key role. This Special Issue gives special focus to the advancement of mechanical alloying, spark plasma sintering and self-propagating high-temperature synthesis methods, as well as to the role of these processes in the development of new materials. [ABSTRACT FROM AUTHOR]

The phase composition and portion of individual phases in advanced high-strength steels (AHSS) CP1000 and DP1000 was studied by complementary microscopic and diffraction techniques. CP1000 and DP1000 steel grades have a high strength-to-density ratio and they are used in many applications in the automotive industry. The microstructure of the CP1000 "complex phase" steel consists of ferrite, bainite, martensite and a small amount of retained austenite. DP1000 is a dual phase steel, which has a structure of a ferritic matrix with islands of martensite and a minor amount of retained austenite. The influence of selected etchants (Nital, LePera, Beraha I, Nital followed by metabisulfite, Nital followed by LePera, and Nital followed by Beraha I) on the microstructure image is described. X-ray diffraction, neutron diffraction and light optical, scanning and transmission electron microscopy were used in this work for advanced characterization of the microstructure and phase composition. The information provided by each technique is critically compared. [ABSTRACT FROM AUTHOR]

Ni-Ti alloys are considered to be very important shape memory alloys with a wide application area including, e.g., biomaterials, actuators, couplings, and components in automotive, aerospace, and robotics industries. In this study, the NiTi46 (wt.%) alloy was prepared by a combination of self-propagating high-temperature synthesis, milling, and spark plasma sintering consolidation at three various temperatures. The compacted samples were subsequently heat-treated at temperatures between 400 °C and 900 °C with the following quenching in water or slow cooling in a closed furnace. The influence of the consolidation temperature and regime of heat treatment on the microstructure, mechanical properties, and temperatures of phase transformation was evaluated. The results demonstrate the brittle behaviour of the samples directly after spark plasma sintering at all temperatures by the compressive test and no transformation temperatures at differential scanning calorimetry curves. The biggest improvement of mechanical properties, which was mainly a ductility enhancement, was achieved by heat treatment at 700 °C. Slow cooling has to be recommended in order to obtain the shape memory properties. [ABSTRACT FROM AUTHOR]

Composite material prepared by spark plasma sintering (SPS) from a powder mixture of AlCrFeSi rapidly solidified alloy and 5 wt. % of Ni particles was studied in this work. It was proven that during SPS compaction at 500 °C, no intermetallic phases formed on the surface of Ni particles. The material exhibited sufficient mechanical properties obtained by tensile testing (ultimate tensile stress of 203 ± 4 MPa, ductility of 0.8% and 0.2% offset yield strength of 156 ± 2 MPa). Tensile samples were pre-stressed to 180 MPa and annealed at 450 and 550 °C for 1 h. Annealing at 450 °C did not lead to any recovery of the material. Annealing at 550 °C caused the full recovery of 0.2% offset yield strength, while the ductility was decreased. The self-healing behaviour originates from the growth of intermetallic phases between the Ni particle and the Al matrix. The sequence of NiAl, Ni2Al3 and NiAl3 intermetallic phases formation was observed. In particular, the morphology of the NiAl3 phase, growing in thin dendrites into the Al matrix, is suitable for the closing of cracks, which pass through the material. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]

FeAlSi intermetallics are materials with promising high-temperature mechanical properties and oxidation resistance. Nevertheless, their production by standard metallurgical processes is complicated. In this study, preparation of powders by mechanical alloying and properties of the samples compacted by spark plasma sintering was studied. Various initial feedstock materials were mixed to prepare the material with the same chemical composition. Time of mechanical alloying leading to complete homogenization of powders was estimated based on the microstructure observations, results of XRD and indentation tests. Microstructure, phase composition, hardness and fracture toughness of sintered samples was studied and compared with the properties of powders before the sintering process. It was found that independently of initial feedstock powder, the resulting phase composition was the same (Fe3Si + FeSi). The combination of hard initial powders required the longest milling time, but it led to the highest values of fracture toughness. [ABSTRACT FROM AUTHOR]

Fe–Al–Si alloys have been previously reported as an interesting alternative to common high-temperature materials. This work aimed to improve the properties of FeAl20Si20 alloy (in wt.%) by the application of powder metallurgy process consisting of ultrahigh-energy mechanical alloying and spark plasma sintering. The material consisted of Fe3Si, FeSi, and Fe3Al2Si3 phases. It was found that the alloy exhibits an anomalous behaviour of yield strength and ultimate compressive strength around 500 °C, reaching approximately 1100 and 1500 MPa, respectively. The results also demonstrated exceptional wear resistance, oxidation resistance, and corrosion resistance in water-based electrolytes. The tested manufacturing process enabled the fracture toughness to be increased ca. 10 times compared to the cast alloy of the same composition. Due to its unique properties, the material could be applicable in the automotive industry for the manufacture of exhaust valves, for wear parts, and probably as a material for selected aggressive chemical environments. [ABSTRACT FROM AUTHOR]

A new strategy was applied to develop nano-quasicrystalline phase in well-known AlNiCo ternary system. This approach was based on electroless Ni-P plating of the starting powders and subsequent ball milling in a protective atmosphere without additional annealing or sintering processes. Microstructural evolution and phase transformation of both raw and coated particles were analyzed by scanning electron microscope (SEM) and X-ray diffraction (XRD), respectively. After 360 min of mechanical alloying, the peaks demonstrating the formation of nano-quasicrystalline phase appeared in XRD pattern of the coated powders, while those in mechanically alloyed raw powders remained mostly unchanged. The formation of nano-quasicrystalline phase in the vicinity of the primary elements was also confirmed by the corresponding selected area diffraction patterns, and images generated by transmission electron microscope (TEM). [ABSTRACT FROM AUTHOR]

This work aims to describe the mechanism of intermediary phases formation in TiAl20 (wt. %) alloy composition during reactive sintering. The reaction between titanium and aluminum powders was studied by in situ diffraction and the results were confirmed by annealing at various temperatures. It was found that the Ti2Al5 phase formed preferentially and its formation was detected at 400 °C. So far, this phase has never been found in this alloy composition during reactive sintering processes. Subsequently, the Ti2Al5 phase reacted with the titanium, and the formation of the major phase, Ti3Al, was accompanied by the minor phase, TiAl. Equations of the proposed reactions are presented in this paper and their thermodynamic and kinetic feasibility are supported by Gibbs energies of reaction and reaction enthalpies. [ABSTRACT FROM AUTHOR]

Iron aluminides are still deeply investigated materials for their use in power plants, automotive and chemical industry, and other sectors. This paper shows that it is possible to strongly improve their oxidation behavior by the addition of silicon. The description of the synergic effect of aluminum and silicon on the oxidation behavior of Fe–Al–Si alloys at 800 °C in air is presented. The oxidation rate, microstructure, phase, and chemical composition of these ternary alloys are compared with the binary Fe–Al and Fe–Si alloys. Results showed that the oxidation of Fe–Al–Si ternary alloys provides an oxide layer based on aluminum oxide with a low concentration of iron and silicon. Below this oxide layer, there is a layer of silicides formed as a result of depletion by aluminum, which forms a secondary oxidation protection. [ABSTRACT FROM AUTHOR]

This work aims to describe the formation of intermetallics in the Ni-Ti-Al system in dependence on the heating rate, which has been determined previously as the crucial factor of thermal explosion self-propagating synthesis (TE-SHS). The tested alloys contained 1–7 wt % aluminum. Thermal analysis has been realized by the optical pyrometer under the conditions of high heating rates up to 110 °C·min−1. TE-SHS process in Ni-Ti-Al system is initiated by exothermic reaction of nickel aluminides Ni2Al3 and NiAl3 at the temperature of 535–610 °C. The next reactions occur in dependence on the heating rate. Samples containing 1–3 wt % of aluminum exhibit the similar initiation temperature as Ni-Ti binary mixture. The samples containing 5 wt % and more of aluminum were fully reacted after sintering at 800 °C with the heating rate of 300 °C·min−1 and the initiation temperature of the TE-SHS was observed close to Al-Al3Ni eutectic temperature (between 630–640 °C). [ABSTRACT FROM AUTHOR]

The compact samples of an Al7075 alloy were prepared by a combination of gas atomization, high energy milling, and spark plasma sintering. The predominantly cellular morphology observed in gas atomized powder particles was completely changed by mechanical milling. The continuous-like intermetallic phases present along intercellular boundaries were destroyed; nevertheless, a small amount of Mg(Zn,Cu,Al)2 phase was observed also in the milled powder. Milling resulted in a severe plastic deformation of the material and led to a reduction of grain size from several µm into the nanocrystalline region. The combination of these microstructural characteristics resulted in abnormally high microhardness values exceeding 300 HV. Consolidation through spark plasma sintering (SPS) resulted in bulk samples with negligible porosity. The heat exposition during SPS led to precipitation of intermetallic phases from the non-equilibrium microstructure of both gas atomized and milled powders. SPS of the milled powder resulted in a recrystallization of the severely deformed structure. An ultra-fine grained structure (grain size close to 500 nm) with grains divided primarily by high-angle boundaries was formed. A simultaneous release of stored deformation energy and an increase in the grain size caused a drop of microhardness to values close to 150 HV. This value was retained even after annealing at 425 °C. [ABSTRACT FROM AUTHOR]