Processing and properties of FeAl-bonded composites

Iron aluminides are thermodynamically compatible with a wide range of ceramics such as carbides, borides, oxides, and nitrides, which makes them suitable as the matrix in composites or cermets containing fine ceramic particulates. For ceramic contents varying from 30 to 60 vol.%, composites of Fe-40 at. % Al with WC, TiC, TiB{sub 2}, and ZrB{sub 2} were fabricated by conventional liquid phase sintering of powder mixtures. For ceramic contents from 70 to 85 vol.%, pressureless melt infiltration was found to be a more suitable processing technique. In FeAl-60 vol.% WC, flexure strengths of up to 1.8 GPa were obtained, even though processing defects consisting of small oxide clusters were present. Room temperature fracture toughnesses were determined by flexure testing of chevron-notched specimens. FeAl/WC and FeAl/TiC composites containing 60 vol.% carbide particles exhibited K{sub Q} values around 20 MPa m{sup 1/2}. Slow crack growth measurements carried out in water and in dry oxygen suggest a relatively small influence of water-vapor embrittlement. It appears therefore that the mechanical properties of iron aluminides in the form of fine ligaments are quite different from their bulk properties. Measurements of the oxidation resistance, dry wear resistance, and thermal expansion of iron aluminide composites suggest many potential applications for these new materials