Simultaneous synthesis and consolidation of nanocrystalline Fe2Al5 and Fe2Al5-Al2O3 by pulsed current activated sintering and their mechanical properties

Nanopowders of Fe, Al and Fe2O3 are fabricated by high energy ball milling. Using the pulsed current activated sintering method, the densification of nanocrystalline Fe2Al5 and Al2O3 reinforced Fe2Al5 composites were simultaneously synthesized and consolidated within two minutes from mechanically activated powders. The advantage of this process is that it allows very quick densification to near theoretical density and prohibition of grain growth in nanostuctured materials. Nanocrystalline materials have received much attention as advanced engineering materials with improved physical and mechanical properties. As nanomaterials possess high strength, high hardness, excellent ductility and toughness, undoubtedly, more attention has been paid to the application of nanomaterials. Not only the hardness but also the fracture toughness of the Fe2Al5-Al2O3 composite was higher than that of monolithic Fe2Al5 due to the addition of the hard phase of Al2O3 and the crack deflection by Al2O3.