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Original Articles

Reaction mechanisms between Al and Fe3O4 powders in the formation of an Al-based metal matrix composite

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Pages 1535-1553 | Received 09 Aug 2008, Accepted 02 May 2009, Published online: 19 Jun 2009
 

Abstract

The reaction mechanisms between Al and Fe3O4 powders were investigated. Differential thermal analysis revealed that a two-step displacement reaction between Al and Fe3O4 took place during sintering. Initially, the Fe3O4 was converted to amorphous FeO at ∼720°C and some of the Al was oxidized to amorphous Al2O3. In the final stage, when the temperature reached ∼840°C, crystalline Al2O3 particles were produced in the molten Al–Fe liquid. The effects of cooling rate on the microstructures were studied. When the Al–Fe liquid was furnace-cooled to room temperature, proeutectic Al3Fe plates, plate-like divorced eutectic Al3Fe and Al2O3 particles were in situ formed in the Al(Fe) matrix. While quenching from 700°C, nanometer-sized Al dendrites and Al–Al6Fe eutectic lamellae were produced in the Al matrix. However, when it was rapidly quenched from 900°C, the size of the proeutectic Al3Fe phases was further reduced and Al6Fe nanorods were found in the Al–Al6Fe eutectics. A model was proposed to describe the transformation of the Al–Fe intermetallics during solidification.

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