Preparation and characterization of iron aluminide based intermetallic alloy from titaniferous magnetite ore

• Published in: Journal of alloys and compounds 2003-09, Vol.359 (1), p.159-168
• Main Authors: Chakraborty, S.P., Sharma, I.G., Menon, P.R., Suri, A.K.
• Format: Article
• Language: English
• Subjects: Cross-disciplinary physics: materials science; rheology; Exact sciences and technology; Materials science; Materials synthesis; materials processing; Materials testing; Metallography; Physics; Powder metallurgy; Powder processing: powder metallurgy, compaction, sintering, mechanical alloying, and granulation; Solid state reactions; Thermal analysis, differential thermal analysis (DTA), differential thermogravimetric analysis; Transition metal alloys
• ISSN: 0925-8388; 1873-4669
• DOI: 10.1016/S0925-8388(03)00197-X

Intermetallic alloys such as iron aluminide (Fe 3Al) display an attractive combination of physical and mechanical properties. It is a potential candidate for application demanding high strength, superior oxidation, sulphidation and corrosion resistance. However, the utilization of this alloy is limited owing to problems of its preparation by conventional techniques and poor room temperature ductility. The present paper is, therefore, an attempt to prepare an Fe 3Al-based alloy (iron aluminide alloy) of composition Fe–17.24Al–5.54Cr–1V–0.05C (wt%) by a non-conventional non-furnace process. The process essentially involves the use of cheap, indigenously available titaniferous magnetite ore containing oxides of iron and vanadium and oxide of chromium that are subsequently co-reduced by aluminium in the presence of excess aluminium and a requisite amount of carbon in a specially designed water-cooled copper reactor. The charge composition is judiciously adjusted to attain the alloy composition by utilizing the exothermicity of the overall reactions. The alloy is further characterized with respect to composition, phases and microstructure and properties such as fabricability, hardness, strength and oxidation resistance were studied to indicate its suitability for high temperature applications.