Synthesis and characterisation of a novel Fe-based nanocomposite by mechanical alloying and spark plasma sintering

ABSTRACT

To improve low hardness and poor corrosion resistance of the Fe-based alloys, Fe–Ti–Al–B–Si–C–P–Cr novel alloy was prepared using mechanical alloying and spark plasma sintering (SPS). Two types of mills, including of high-energy planetary (HEP) and SPEX(S) ball mills (BM) were used to reach the solid solution. Mechanical alloying by the HEP route led to the formation of the Fe(α) phase after 60 h, while its milling after 15 h by high-energy SPEX mill led to the formation of the Fe(α) solid solution. After sintering of as-milled powders by SPS, the composite of Fe (α)/nanocrystalline was obtained. The micro-hardness of the HEP–SPS and the S–SPS samples obtained about 689.5 ± 0.15 and 2068.5 ± 0.18 HV_0.3, respectively. The lowest corrosion current density and the highest polarization resistance were related to the HEP–SPS sample and was calculated to be 0.51 µA/cm² and 41.668 KHz/cm², respectively.

KEYWORDS:

• Fe-based alloy
• mechanical alloying
• spark plasma sintering
• microstructural
• corrosion performance
• solid solution

Acknowledgement

This study was supported by Islamic Azad University of Ahvaz Branch [Grant number 1069608170008]. Hereby, the authors express our thanks and appreciation to the research unit University of Ahvaz.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Notes on contributors

Mehdi Boroujerdnia

Dr. Mehdi Boroujerdnia and Dr. Ali Obeydavi are the materials engineering faculty members of Islamic Azad University, Ahvaz Branch. Dr. Ali Obeydavi is also a postdoctoral researcher of department of materials engineering at Isfahan University of Technology. Research interests of Dr. Boroujerdnia are nanotechnology, powder metallurgy, coatings and characterization of materials properties such as wear, corrosion and mechanical properties. Research interests of Dr. Obeydavi are high entropy alloys, metallic glasses, thin films and coatings, nanotechnology, synthesis by sol-gel, mechanical alloying, powder metallurgy, spark plasma sintering, sputtering deposition and air plasma spray, characterization of materials properties such as wear, corrosion and mechanical properties.

Ali Obeydavi

Dr. Mehdi Boroujerdnia and Dr. Ali Obeydavi are the materials engineering faculty members of Islamic Azad University, Ahvaz Branch. Dr. Ali Obeydavi is also a postdoctoral researcher of department of materials engineering at Isfahan University of Technology. Research interests of Dr. Boroujerdnia are nanotechnology, powder metallurgy, coatings and characterization of materials properties such as wear, corrosion and mechanical properties. Research interests of Dr. Obeydavi are high entropy alloys, metallic glasses, thin films and coatings, nanotechnology, synthesis by sol-gel, mechanical alloying, powder metallurgy, spark plasma sintering, sputtering deposition and air plasma spray, characterization of materials properties such as wear, corrosion and mechanical properties.

Masoud Sabzi

Mr. Masoud Sabzi his BSc in materials science and engineering from Islamic Azad University (Dezful Branch) and Master degree in materials science and engineering from Islamic Azad University (Ahvaz Branch). His research interests are on properties of welded joints, corrosion science and self-healing mechanisms, welding of Hadfield steel, PCGTAW-CCGTAW process, wear & corrosion behavior of coatings and alloys, the fatigue of high carbon steels, fracture toughness of welded joining, microstructure and phase characterization in high-alloy steels, and layer-deposition of the ceramic-based coating. They also act as consultants in the industry.