Wet Milling of Fe/Al/Al ₂ O ₃ and Fe ₂ O ₃ /Al/Al ₂ O ₃ Powder Mixtures

Abstract

Wet milling of Al 2 O 3 ‐aluminide alloy (3A) precursor powders in acetone has been investigated by milling Fe/Al/Al 2 O 3 and Fe 2 O 3 /Al/Al 2 O 3 powder mixtures. The influence of the milling process on the physical and chemical properties of the milled powders has been studied. Particle refinement and homogenization were found not to play a dominant role, whereas plastic deformation of the metal particles leads to the formation of dislocations and a highly disarranged polycrystalline structure. Although no chemical reactions among the powder components in Fe 2 O 3 /Al/Al 2 O 3 powder mixtures were observed, the formation of a nanocrystalline, ordered intermetallic FeAl phase in Fe/Al/Al 2 O 3 powder mixtures caused by mechanical alloying was detected. Chemical reactions of Fe and Al particle surfaces with the atmosphere and the milling media lead to the formation of highly porous hydroxides on the particle surfaces. Hence the specific surface area of the powders increases, while the powder density decreases during milling. The fraction of Fe oxidized during milling was determined to be 0.13. The fraction of Al oxidized during milling strongly depends on the metal content of the powder mixture. It ranges between 0.4 and 0.8.