Fe3Al-based iron aluminides have been of interest for many years because of their excellent oxidation and sulfidation resistance. However, limited room temperature ductility (<5%) and a sharp drop in strength above 600 °C have limited their consideration for use as structural materials. Recent improvements in tensile properties, especially improvements in ductility produced through control of composition and microstructure, and advances in the understanding of environmental embrittlement in intermetallics, including iron aluminides, have resulted in renewed interest in this system for structural applications. The purpose of this paper is to summarize recent developments concerning Fe3Al-based aluminides, including alloy development efforts and environmental embrittlement studies. This report will concentrate on literature published since about 1980, and will review studies of fabrication, mechanical properties, and corrosion resistance that have been conducted since that time.

‘‘Amorphous’’ Ni60Nb40 has been prepared by mechanical alloying of elemental nickel and niobium powders in a laboratory ball mill in controlled environments. X-ray diffraction was used to follow the progress of the mechanical alloying which eventually produced ‘‘amorphous’’ diffraction patterns similar to those for liquid quenched amorphous Ni60Nb40. Crystallization behavior was measured by differential scanning calorimetry for the mechanically alloyed and liquid quenched material. The differences that were observed in this behavior, and in the products of crystallization, may be attributed to impurities (especially oxygen) introduced during mechanical alloying.

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The effects of the addition of chromium on several properties of Fe3Al, including tensile strength and ductility, fracture behavior, and slip and dislocation characteristics, were studied. Alloying with up to 6 at. % chromium results in an increase in room temperature ductility from approximately 4% to 8–10%. Along with this increase in ductility, the addition of chromium produces a change in fracture mode from transgranular cleavage to a mixed mode of intergranular-transgranular cleavage, and a change in slip behavior from coarse straight slip to fine wavy slip. These phenomena are discussed in terms of the effect of chromium on the antiphase boundary energies and dislocation characteristics.