Abstract
The formation of iron aluminide coating on an Al surface by mechanical alloying with Al–Fe powder of various compositions was investigated. When the amount of Fe powder in the starting powder is >50 at.‐%, an FeAl containing coating layer is formed. As the mass ratio of the balls and substrate to the powder in the pot is small, the formation of FeAl phase is achieved in a short time. The obtained FeAl containing coating layer has high hardness and fracture toughness. When the amount of Fe powder in starting powder is <50 at.‐%, a coating layer consisting of FeAl and Fe2Al5 is formed. The coexistence of Fe2Al5 in the coating layer causes the coating layer to be more brittle.
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