Abstract

Iron–alumina (Fe–Al2O3) composites were prepared by pressureless sintering, using Bayan Obo iron concentrate and alumina as the main raw materials; activated carbon was added as the reducing agent. The effects of different carbon/oxygen ratios (C/O ratios) on the phase composition, the mechanical and the corrosion-resistant properties of the materials were investigated. Due to the presence of pyrite, sulfide precipitate takes place around the iron particles, and it is transformed from FeS to MnS with increasing C/O ratio. It was found that crack propagation can be effectively hindered by MnS. The results indicate that the orientation relationships between the Fe and MnS are Fe (100) ‖ MnS (002). However, there is no specific orientation relationship between Fe and FeS. It was found that the phase interface between Fe and MnS is coherent interface since the misfit between Fe (100) and MnS (002) was 2.1%. The performance of sample with C/O ratio of 3:1 were found to be favorable, with flexural strength was 301 MPa, Vickers hardness was 13.12 GPa, the acid resistance was 93.40% and the alkali-resistance was 98.20%.

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