Influence of mechanical activation time,annealing, and Fe/O ratio on Fe3O4/Fe composites formation from Fe2O3 and Fe powders mixture

Commercially, iron (α-Fe) and hematite (α-Fe₂O₃) powders were used for the synthesis of composite powders of Fe₂O₃/Fe type by mechanical milling. Several ratios of Fe₂O₃/Fe were chosen for the composite synthesis; the atomic percent of oxygen in the starting mixtures ranged from 21 to 46 %. The Fe₂O₃/Fe composite samples with various Fe/O ratios were milled for different milling times. The milled composite samples were subjected to the heat treatments in argon up to 900 °C. During the heat treatment at temperatures that do not exceed 550 °C, Fe₃O₄/Fe composite particles are formed by the reaction between the Fe₂O₃ and Fe. Further increase of the heat treatment up to 700 °C leads to the reaction of the Fe₃O₄/Fe composite component phases, resulting thus in the formation of FeO/Fe composite. The heat treatment up to 900 °C of the Fe₂O₃/Fe leads to the formation of a composite of FeO/Fe₃O₄/Fe independent of the milling time and Fe₂O₃/Fe ratios. The onset temperatures of the Fe₃O₄ and FeO formations decrease upon increasing the milling time. Another important aspect is that, in the case of the same milling time but with a large amount of iron into the composite powder the formations temperatures of Fe₃O₄ and FeO are also decreasing. The influence of the mechanical activation time, heat treatment temperature, and Fe/O ratio on the formation of the (Fe₃O₄, FeO)/Fe composite from Fe₂O₃+Fe precursor mixtures was studied by differential scanning calorimetry and X-ray diffraction techniques.