Chemical reduction synthesis of iron aluminum powders

Abstract

In this study, a chemical reduction synthesis method of iron aluminum (FeAl) nano-dimensional intermetallic powders is described. The process has two stages: a salt reduction and solvent evaporation by a heat treatment at 1100°C. The precursors of the synthesis are ferric chloride, aluminum foil chips, a mix of Toluene/THF in a 75/25 volume relationship, and concentrated hydrochloric acid as initiator of the reaction. The reaction time was 20 days, the product obtained was dried at 60 °C for 2 h and calcined at 400, 800, and 1100 °C for 4 h each. To characterize and confirm the obtained synthesis products, X-Ray Diffraction (XRD), and Scanning Electron Microscopy (SEM) techniques were used. The results of morphology and chemical characterization of nano-dimensional powders obtained showed a formation of agglomerated particles of a size range of approximately 150 nm to 1.0 µm. Composition of powders was identified as corundum (Al2O3), iron aluminide (FeAl3), and iron-aluminum oxides (Fe0.53Al0.47)2O3 phases. The oxide phases formation were associated with the reaction of atmospheric concentrationfree oxygen during synthesis and sintering steps, reducing the concentration of the iron aluminum phase.