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Transient liquid phase sintering of high density Fe3Al using Fe and Fe2Al5–FeAl2 powders Part 2 – Densification mechanism analysis

Abstract The use of Fe2Al5–FeAl2 prealloyed powders and heating rates >150 K min−1 overcomes the formation of density restricting Kirkendall porosity in the Fe–Al system. X-ray diffraction, electron probe micro analysis and differential thermal analysis suggest that the absence of a persistent liquid, experienced when liquid phase sintering with elemental powders, is overcome. Homogenisation is greater during heating at a rate of 20 K min−1 than for 150, 250 or 400 K min−1 and homogenous Fe3Al forms across the compact at temperatures below the melting point of the liquid forming constituent, indicating that a liquid will not form under such processing conditions. The maximum density achieved under the processing conditions in the present study is 92% of theoretical density. The presence of large pores shortly after liquid formation suggests that the remaining porosity is largely due to powder agglomeration during mixing.