Synthesis of a pure FeAl with a density greater than 95% of theoretical density by optimizing effective factors

In this study, the FeAl with a density greater than 95% of the theoretical density was synthesized by optimizing the compacting pressure, the particle size of iron and aluminum, and the pre-heating temperature. To do so, the products of the samples which were examined by the change of the particle size of 10µm and 50µm, the pre-heating temperatures of 25°C, 287°C and 550°C and the compacting pressures of 400MPa, 500MPa, and 600MPa, were studied. According to the appearance, composition, density, hardness, and oxidation resistance, the optimum sample was determined. The optimal FeAl had a density of more than 95% of the theoretical density, which was prepared using the particle size of 10/10 of iron and aluminum, the pre-heating temperature of 550°C, and the compacting pressure of 500 MPa. The duration of the pre-heating and the synthesis was also 5 and 3h, respectively. It was found that without pre-heating, there is no possibility of producing a compact and dense product. It was also found that the particle size of the iron is more effective than the particle size of aluminum to achieve the qualified FeAl product.