Iron Aluminide Composites
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ABSTRACT Iron aluminides with the B2 structure are highly oxidation and corrosion resistant. They are thermodynamically compatible with a wide range of ceramics such as TiC, WC, TiB 2, and ZrB 2. In addition, liquid iron aluminides wet these ceramics very well. Therefore, FeAI/ceramic composites may be produced by techniques such as liquid phase sintering of powder mixtures, or pressureless melt infiltration of ceramic powders with liquid FeAl. These techniques, the resulting microstructures, and their advantages as well as limitations are described. Iron aluminide composites can be very strong. Room temperature flexure strengths as high as 1.8 GPa have been observed for FeAl/WC. Substantial gains in strength at elevated temperatures (1073 K) have also been demonstrated. Above 40 vol.% WC the room temperature flexure strength becomes flaw-limited. This is thought to be due to processing flaws and limited interfacial strength. The fracture toughness of FeAl/WC is unexpectedly high and follows a rule of mixtures. Interestingly, sufficiently thin (
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