Abstract
Iron powders having average particle sizes of ~40 µm are mechanically mixed thoroughly with aluminum powders ranging from 1 to 10 in wt. %, with an average particle size of ~10 µm. Two different powder metallurgy (PM) techniques, cold and hot pressing, are used to study the effect of the additive element powder on the mechanical properties, wear properties, and the microstructure of the iron based alloys. The hot pressing technique was performed at a temperature reaching up to 500 °C at 445.6 MPa. The cold pressing technique was performed at 909 MPa at room temperature. By increasing the Al content to 10 wt. % in the base Fe-based matrix, the Brinell hardness number was decreased from 780 to 690 and the radial strength from 380 to 228 MPa with reductions of 11.5% and 40%, respectively. Improvement of the wear resistance with the increase addition of the Al powder to the Fe matrix up to five times was achieved, compared to the alloy without Al addition for different wear parameters: wear time and sliding speed.
Highlights
Some of the advantages of powder metallurgy (PM) alloys include minimum cost, high flexibility, ability to be shaped into complicated products, use metastable structures, and wide-ranging reinforcement levels [1,2]
Hot pressing (HP) technique followed by heat treatment was performed to avoid the limitations observed under the cold compaction technique
The compact density and porosity are affected by the pressing temperature, as shown in Figure 6b; in other words, the density increases by increasing the temperature, which leads to porosity minimization
Summary
Some of the advantages of powder metallurgy (PM) alloys include minimum cost, high flexibility, ability to be shaped into complicated products, use metastable structures, and wide-ranging reinforcement levels [1,2]. It is characterized by its ordered body centered cubic (BCC) structure [10] It has been an important subject of interest, commercially, due to its outstanding oxidation resistance, acceptable strength at high temperatures reaching ≈530 ◦ C, and minimum density (5.76–6.32 g/cm depending on Fe/Al ratio) when related to other iron based alloys utilized in market [11]. The present work aims to control and optimize the production of processing parameters, through suitable compaction die design to get dense PM parts, and study the influence of the production methods on the structure density, hardness and wear properties of the iron alloys containing aluminum as a dispersed
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