Microstructure formation of Al-Fe-Mn-Si aluminides by pressureassisted reactive sintering of elemental powder mixtures

This paper presents the results of an investigation aimed at understanding microstructure formation of Al-Fe-Mn-Si intermetallics during pressure-assisted reactive sintering of elemental powders. The proportion of elements was selected such that the composition of the product was 55 wt % Al, 17 wt % Si, 14 wt % Mn, and 14 wt % Fe. Experiments were conducted at temperatures between 600 and 800°C, using compaction stresses of up to 20 MPa. Rietveld analysis of x-ray diffraction patterns of fully processed samples showed that the powders were transformed into a mixture of α-Al₉FeMnSi and β-Al ₉FeMn₂Si phases. However, as temperature and pressure were increased, the α-Al₉FeMnSi phase was transformed into the β-Al₉FeMn₂Si phase. Differential Thermal Analysis, as well as microstructural characterization by scanning electron microscopy and x-ray diffraction, showed that these intermetallics do not form directly from the powder mixtures. Rather, they are the result of metallurgical reactions between a molten Al-Si solution and various intermediate phases formed during reactive sintering.