Microstructure Formation of Al-Fe-Mn-Si Aluminides by Pressure-Assisted Reactive Sintering of Elemental Powder Mixtures

Abstract

This paper presents the results of an investigation aimed at understanding microstructure formation of Al-Fe-Mn-Si intermetallics during pressure-assisted reactive sintering of elemental powders. The proportion of elements was selected such that the composition of the product was 55 wt % Al, 17 wt % Si, 14 wt % Mn, and 14 wt % Fe. Experiments were conducted at temperatures between 600 and 800°C, using compaction stresses of up to 20 MPa. Rietveld analysis of x-ray diffraction patterns of fully processed samples showed that the powders were transformed into a mixture of Al9FeMnSi and Al9FeMn2Si phases. However, as temperature and pressure were increased, the Al9FeMnSi phase was transformed into the Al9FeMn2Si phase. Differential Thermal Analysis, as well as microstructural characterization by scanning electron microscopy and x-ray diffraction, showed that these intermetallics do not form directly from the powder mixtures. Rather, they are the result of metallurgical reactions between a molten Al-Si solution and various intermediate phases formed during reactive sintering.