Al-x wt.% Fe bulk alloys were fabricated from a powder mixture of pure Al and x wt.% of Fe, where x = 2 wt.%, 5 wt.% and 10 wt.%. Initially, as-mixed mixtures were processed using a mechanical-alloying (MA) technique in an attritor for 4 h. The milling was performed in an argon atmosphere at room temperature followed by the sintering of the milled powders in a high-frequency induction furnace to produce bulk samples. Scanning electron microscopy (SEM) was used to study the morphology of the produced alloys, and X-ray diffraction (XRD) to determine the phases formed after the sintering process and their crystallite size. The corrosion behavior of the fabricated samples was studied by immerging them in a 3.5% sodium chloride (NaCl) solution at room temperature using cyclic-polarization (CP) and electrochemical-impedance-spectroscopy (EIS) techniques. The SEM results showed that Fe was uniformly distributed in the Al matrix, and XRD revealed the formation of Al and intermetallic, i.e., Al6Fe and Al13Fe4, phases in the Al-Fe alloys after sintering. The hardness of the Al-Fe alloys was increased with the addition of Fe due to the formation of intermetallic compounds. Electrochemical results showed that there was a proportional relationship between the percentage of Fe additives and corrosion potential (Ecorr) where it shifted toward a nobler direction, while corrosion current density (icorr) and corrosion rate decreased with an increasing Fe%. This observation indicates that the addition of Fe into an Al matrix leads to an improvement in the corrosion resistance of the alloys.
In the present study, a novel choice of sheath materials for drawing long superconducting MgB2 wire by using the powder-in-tube technique (PIT) is reported. This would eliminate the need for an intermediate strain-relieving annealing process and would reduce the time and cost of fabrication. Our strategy involved the use of a composite sheath instead of a sheath made of a single material. The relatively inert Fe constituted the inner sheath around the MgB2 powder while the Cu—which is capable of efficient heat dissipation—was used as the outer sheath. Important mechanical properties of the wire such as elastic modulus, ultimate tensile strength, yield strength, hardness, and microstructure were carefully studied at different stages of the drawing process using tensile and microhardness tests. To clearly delineate the effect of Cu cladding on the ductile behavior of the iron sheath, another MgB2 wire with only an Fe sheath was prepared; its mechanical properties were measured and compared with those of the composite Cu–Fe-sheathed MgB2 wire. After a few drawing steps, the composite Cu–Fe-sheathed wire showed a lower elastic modulus and tensile strength than those of its Fe sheath counterpart. While both types of wires showed an increase in hardness as the drawing process progressed, the composite-sheath wire consistently showed a lower hardness than that of its counterpart, implying its lower susceptibility to fracture; it can therefore be safely drawn to small diameters without the need for intermediate annealing during the wire drawing process.
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