Synthesis and characterization of zirconium carbide-reinforced iron-based composite

The ZrC-reinforced iron-based composites (Fe–ZrC) were synthesized by a simple, cost-effective process involving aluminothermic reduction of blue dust (Fe2O3) and zircon sand (ZrSiO4) in the presence of carbon. The aluminothermic reduction of blue dust and zircon sand, being highly exothermic in nature, essentially leads to a self-propagating high-temperature synthesis (SHS) of the Fe–ZrC composite. The composites were synthesized with varying percentages of aluminum and carbon in the charge mixture. Both aluminum and carbon play important role in the reduction of zirconia. The composites have been subsequently characterized by techniques of optical microscopy, scanning electron microscopy (SEM), and X-ray diffraction (XRD). It has been found that along with ZrC, other phases (Fe3Al, FeZr4) also formed depending upon the charge composition. The charge composition has been optimized to get reasonable recovery of Zr in the form of ZrC. The mechanical properties, such as hardness and wear resistance of the composite, corresponding to the optimum charge composition have also been evaluated. The composite has been found to possess promising abrasive wear resistance property along with good high-temperature stability.