Reaction mechanisms between Al and Fe3O4 powders in the formation of an Al-based metal matrix composite

The reaction mechanisms between Al and Fe₃O₄ powders were investigated. Differential thermal analysis revealed that a two-step displacement reaction between Al and Fe₃O₄ took place during sintering. Initially, the Fe₃O₄ was converted to amorphous FeO at ～720°C and some of the Al was oxidized to amorphous Al₂O₃. In the final stage, when the temperature reached ～840°C, crystalline Al₂O₃ particles were produced in the molten Al–Fe liquid. The effects of cooling rate on the microstructures were studied. When the Al–Fe liquid was furnace-cooled to room temperature, proeutectic Al₃Fe plates, plate-like divorced eutectic Al₃Fe and Al₂O₃ particles were in situ formed in the Al(Fe) matrix. While quenching from 700°C, nanometer-sized Al dendrites and Al–Al₆Fe eutectic lamellae were produced in the Al matrix. However, when it was rapidly quenched from 900°C, the size of the proeutectic Al₃Fe phases was further reduced and Al₆Fe nanorods were found in the Al–Al₆Fe eutectics. A model was proposed to describe the transformation of the Al–Fe intermetallics during solidification.