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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]

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]

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]

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]