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<p>Binary iron-aluminum (Fe-Al) intermetallic alloys have unique properties that make them ideal for many industrial applications. These include metallurgy, where they are used as master alloys, and mechanical engineering, where they are used for components that require high abrasion and corrosion resistance. However, conventional methods for producing Fe-Al alloy surfaces or components are often complex and multi-stage, underscoring the need for more energy-efficient approaches. One promising alternative is the single-stage aluminothermic processing of thermite charges. Several factors influence the final properties of the cast metal product obtained through this method, including the initial chemical composition and the temperatures of the charge and refractory materials. Based on previous experimental results, which included data on melt-jet temperature, metal phase mass, density, and final alloy composition, this paper presents a&#xa0;comparative analysis of how these factors influence the microstructure of Fe-Al intermetallic alloys. These alloys were formed by exothermic processing of thermite charges containing 25&#xa0;to 60 wt % of aluminum. Analysis presented in this work identified a&#xa0;processing method that maximizes the aluminum content in the final alloys. Additionally, the formation of compositionally homogeneous and heterogeneous structures was characterized and the influence of different thermal conditions on grain size was investigated.</p>

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Microstructure of binary iron-aluminum alloys produced by aluminothermy

  • 期刊论文

  • 发表日期：

    2026年1月15日

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  • S. G. Zhilin,
  • V. V. Predein,
  • V. A. Khudyakova,
  • N. A. Bogdanova

摘要

Binary iron-aluminum (Fe-Al) intermetallic alloys have unique properties that make them ideal for many industrial applications. These include metallurgy, where they are used as master alloys, and mechanical engineering, where they are used for components that require high abrasion and corrosion resistance. However, conventional methods for producing Fe-Al alloy surfaces or components are often complex and multi-stage, underscoring the need for more energy-efficient approaches. One promising alternative is the single-stage aluminothermic processing of thermite charges. Several factors influence the final properties of the cast metal product obtained through this method, including the initial chemical composition and the temperatures of the charge and refractory materials. Based on previous experimental results, which included data on melt-jet temperature, metal phase mass, density, and final alloy composition, this paper presents a comparative analysis of how these factors influence the microstructure of Fe-Al intermetallic alloys. These alloys were formed by exothermic processing of thermite charges containing 25 to 60 wt % of aluminum. Analysis presented in this work identified a processing method that maximizes the aluminum content in the final alloys. Additionally, the formation of compositionally homogeneous and heterogeneous structures was characterized and the influence of different thermal conditions on grain size was investigated.