Abstract
An Al-Fe-Cr-Zr alloy is currently being developed for elevated temperature service utilizing rapid solidification technology. The inert gas atomized powder has been assessed microstructurally and the solidification behaviour interpreted as a function of particle size. It was significant that both fine and coarse powders exhibited structures created by solute trapping during the initial stages of solidification. An unidentified phase (or possibly phases) was detected by X-ray and electron diffraction and shown to form at cell boundaries. Zirconium was retained in solid solution during solidification of all powder structures and subsequently precipitated as fine particles of the metastable Al3Zr phase during heat treatment. This precipitation was extremely fine and deemed suitable for elevated temperature strengthening. In contrast, the iron and chromium additions partition to the cell boundaries and precipitate during heating to their respective equilibrium compounds.
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