Mechanochemical behavior of Fe₂O₃–Al–Fe powder mixtures to produce Fe₃Al–Al₂O₃ nanocomposite powder

Mechanical treatment of Fe₂O₃, Al and Fe powder mixtures was carried out in a high energy ball mill to synthesize Fe₃Al–Al₂O₃ intermetallic matrix nanocomposite. Different compositions including 3Fe + Al, Fe₂O₃ + 2Al, 3Fe₂O₃ + 8Al and Fe₂O₃ + 3Al+Fe were chosen in this study. Phase development and structural changes occurring during ball milling were investigated by X-ray diffractometry (XRD) and scanning electron microscopy (SEM). The results showed that during MA, Fe₂O₃, Al, and Fe react to give a nanocrystalline Fe₃Al intermetallic compound matrix. The presence of pure Fe in initial powder mixture changed the modality of mechanochemical process from sudden to gradual reaction. The Fe₃Al–Al₂O₃ compound had a finer microstructure and particles size compared to the Fe₃Al compound.