Energy & Environment Management_logo

The Al2O3 particle reinforced Al-Fe composites fabricated through an in-situ reaction of Fe2O3 powders in Al melts

Authors

  • Hao Lian

    Author

  • Wenlong Yu

    Author

  • Zhiming SHI

    Inner Mongoli University of Technology

    Author

DOI:
https://doi.org/10.63333/eem.v2n11
Keywords:
Al-Fe; composite; in-situ reaction
Abstract

Al-Fe alloys possess excellent ability to resist heat and wear. However, their mechanical properties are greatly deteriorated due to the coarse needle-like and plate-like Al3Fe phases segregating the soft Al matrix. In this study, the Al2O3 particle-reinforced Al-1.8 wt% Fe and Al-5.0 wt% Fe composites were prepared via an in-situ reaction of Fe2O3 powders in Al melts, the effects of Al2O3 particles on microstructure and mechanical properties were systematically investigated. Results show that the composites can be prepared through a reduction reaction of Fe2O3 powders in stirring Al melts at 1200 ℃ for 30 min. The densely dispersed Al2O3 particles refine the microstructure by inhibiting growths of α-Al grains and Al3Fe phases. The mechanical properties of composites are improved by grain refinement and secondary-phase strengthening. The yield strength, tensile strength, elongation, and hardness are increased by 32.3%, 52.7%, 57.1%, and 28.8% for Al-1.8 Fe composite and 18.0%, 51.1%, 150.0%, and 21.1% for Al-5 Fe composite respectively when compared with their corresponding alloys. These composites, combined with high strength, plasticity, and hardness, are promising materials for applications in energy and environment fields.

Author Biographies
  1. Hao Lian

    Doctor student

  2. Wenlong Yu

    Master student

References

[1] Luo, S.X, Shi, Z.M, Li, N.Y, Lin, Y.M, Liang, Y.H, Zeng, Y.D. (2019). Crystallization inhibition and microstructure refinement of Al-5Fe alloys by addition of rare earth elements, J. Alloy Comp. 789, 90–99. https://doi.org/10.1016/j.jallcom.2019.03.071.

[2] Liang, Y.H, Shi, Z.M, Li, G.W, Zhang, R.Y, Zhao, G. (2019), Effects of Er addition on the crystallization characteristic and microstructure of Al-2wt%Fe cast alloy, J. Alloy Comp. 781, 235–244. https://doi.org/10.1016/j.jallcom.2018.12.063.

[3] Liang, Y.H, Shi, Z.M, Li, G.W, Zhang, R.Y, Li, M. (2019). Effects of rare earth modification on microstructure refinement and mechanical properties of Al-2 wt%Fe alloys, Mater. Res. Express 6, 106504 https://doi.org/10.1088/2053-1591/ab35bd.

[4] Song, X.Y, Gao, M.Q, Yang, B.W, Guan, R.G. (2022) , Modification and refinement of Fe-containing phases, mechanical properties and strengthening mechanisms in Al–Fe alloys via Cr alloying and continuous rheo-extrusion, Mater. Sci. Eng, A850, 143557. https://doi.org/10.1016/j.msea.2022.143557.

[5] Vončina, M, Medved, J, Steinacher, M, Ozimič, K. (2025). The influence of La and Ce additions on the solidification of alloys From the Al–Fe system, J. Therm. Anal. Calorim. 150, 873–882. https://doi.org/10.1007/s10973-024-13009-7.

[6] Qin, L.M, Tang, P, Meng, S.X. (2024). Effect of Ni addition on the microstructure, conductivities and mechanical properties of as-cast Al-Fe alloys, J. Alloy Comp. 986, 174160. https://doi.org/10.1016/j.jallcom.2024.174160.

[7] Nayak, S.S, Chang, H.J, Kim,D.H, Pabi, S.K. (2011) , Formation of metastable phases and nanocomposite structures in rapidly solidified Al–Fe alloys, Mater. Sci. Eng., A528, 5967-5973. https://doi.org/10.1016/j.msea.2011.04.028.

[8] Medvedev, A.E, Zhukova, O.O, Kazykhanov, V.U, Shaikhulova, A.F, Enikeev, N.A. (2022). On the effect of ECAP and subsequent cold rolling on the microstructure and properties of electromagnetically cast Al–Fe alloys, Int. J. Lightweight Mater. Manuf. 5, 484-495. https://doi.org/10.1016/j.ijlmm.2022.06.001.

[9] Chen, J.Q, Liu, C, Guan, R.G, Wen, F, Zhou, Q.Y, Zhao, H.J. (2020). Improving the comprehensive mechanical property of the rheo-extruded Al–Fe alloy by severe rolling deformation, J Mater Res Technol. 9, 1768–1779. https://doi.org/10.1016/j.jmrt.2019.12.008.

[10] Rong, X.D, Zhao, D.D, He, C.N, Zhao, N.Q. (2024). Review: recent progress in aluminum matrix composites reinforced by in situ oxide ceramics, J. Mater. Sci. 59, 9657–9684. https://doi.org/10.1007/s10853-023-09120-z.

[11] Lian, H, Shi, Z.M, Yu, W.L, Wang, Y, Wang, W.B, Pang, N. (2026) . Improvement of microstructure and mechanical property of Al–2Fe alloy through an in-situ reaction of Fe2O3 powder in Al–Mg melts, J Mater Res Technol. 411, 630–1643. https://doi.org/10.1016/j.jmrt.2026.01.072.

[12] Su, H, Gao, W.L, Feng, Z.H, Lu, Z. (2012) , Processing, microstructure and tensile properties of nano-sized Al2O3 particle reinforced aluminum matrix composites, Mater. Design 36, 590–596. https://doi.org/10.1016/j.matdes.2011.11.064.

[13] Wang, H.M, Li, G.R, Zhao, Y.T, Chen, G. (2010). In situ fabrication and microstructure of Al2O3 particles reinforced aluminum matrix composites, Mater. Sci. Eng., A527 , 2881-2885. https://doi.org/10.1016/j.msea.2010.01.022.

[14] Zhu, H.G, Ai, Y.L, Li, J.L, Min, J, Chu. (2011), In situ fabrication of a-Al2O3 and Ni2Al3 reinforced aluminum matrix composites in an Al–Ni2O3 system, Adv. Powder. Technol. 22, 629–633. https://doi.org/10.1016/j.apt.2010.09.016.

[15] Jia, L.J, Rong, X.D, Zhao, D.D, Zhang, X, He, C.N, Zhao, N.Q. (2021). Microstructural characteristic and mechanical properties of the in-situ MgAl2O4 reinforced Al matrix composite based on Al-Mg-ZnO system, J. Alloy Comp. 891, 161991. https://doi.org/10.1016/j.jallcom.2021.161991.

[16] Li, H, Zhang, C, Han, X.D, Jiao, L, Shen, W.M, Song, Z.Y, Wang, J.H, Nie, Z.H, Shcheretskyi, O. (2025). Study on microstructural evolution and strengthening‑toughening mechanisms of aluminum matrix composites fabricated by hot rolling and friction stir processing, J. Mater. Sci. 60, 15064–15086. https://doi.org/10.1007/s10853-025-11369-5.

[17] Patel, S.K, Shi, L. (2025). Recent Advances in Ceramic-Reinforced Aluminum Metal Matrix Composites: A Review, Alloys 4, 18. https://doi.org/10.3390/alloys4030018.

[18] Kai, X.Z, Huang, S.M, Wu, L, Tao, R, Peng, Y.J, Mao, Z.M, Chen, F, Li, G.R, Chen, G, Zhao, Y.T. (2019). High strength and high creep resistant ZrB2/Al nanocomposites fabricated by ultrasonic-chemical in-situ reaction. J. Mater. Sci. Technol. 35, 2107–2114. https://doi.org/10.1016/j.jmst.2019.04.020.

[19] Gao, T, Liu, L.Y, Li, M.Y, Sun, Y, Wu, Y.Y, Liu, X.F. (2023). Design of Al based composites reinforced with in–situ Al2O3, AlB2 and Al13Fe4 particles, Compos. Commun. 40, 101629. https://doi.org/10.1016/j.coco.2023.101629.

[20] Azimi-Roeen, G, Kashani-Bozorg, S.F, Nosko, M, Švec, P. (2017). Reactive mechanism and mechanical properties of in-situ hybrid nano-composites fabricated from an Al–Fe2O3 system by friction stir processing, Mater. Charact. 127, 279–287. https://doi.org/10.1016/j.matchar.2017.03.007.

[21] Zhao, P.F, Shi, Z.M, Wang, X.F, Li, Y.Z, Cao, Z.Y, Zhao, M.D, Liang, J.H. (2023). A Review of the Laser Cladding of Metal-Based Alloys, Ceramic-Reinforced Composites, Amorphous Alloys, and High-Entropy Alloys on Aluminum Alloys, Lubricants 11, 482. https://doi.org/10.3390/lubricants11110482.

[22]Ye, D.L, Hu, J.H, Handbook of Practical Inorganic Thermodynamic Data. 2nd ed. Metallurgical industry press, Beijing 2002.

[23] Guo, Z.F, Liu, J, Sun, C.N, Maleksaeedi, S, Bi, G, Tan, M.J, Wei, J. (2014). Effects of nano-Al2O3 particle addition on grain structure evolution and mechanical behaviour of friction-stir-processed Al, Mater. Sci. Eng., A 602, 143–149. https://doi.org/10.1016/j.msea.2014.02.022.

[24] Ramezani, A, Jamshidi Avdal, H, Jamaati, R. (2025). Influence of Al2O3 addition on microstructure, mechanical strength, and wear behavior of AA7075-Al2O3 matrix composites fabricated using deformation-driven metallurgy, Rineng. 26, 104714. https://doi.org/10.1016/j.rineng.2025.104714.

[25] Xu, T, Li, G.R, Xie, M.L, Liu, M, Zhang, D, Zhao, Y.T, Chen, G, Kai, X.Z. (2019) Microstructure and mechanical properties of in-situ nano γ-Al2O3p/A356 aluminum matrix composite, J. Alloy Comp. 787, 72–85. https://doi.org/10.1016/j.jallcom.2019.02.045.

[26] Gyarmati, G, Erdélyi, J. (2025). Intermetallic phase control in cast aluminum alloys by utilizing heterogeneous nucleation on oxides, Metals 15, 404. https://doi.org/10.3390/met15040404.

[27] Qian, D.H, Wang, Y.F, Yao, Z.H, Chen, J, Yi, H, Chi, Y.M. (2025). Research Progress on Interfacial Bonding and Strengthening of Aluminum Matrix Composites, Int. J. Pr. Eng. Man-Gt. 6, 2288–6206 https://doi.org/10.1007/s40684-025-00798-x.

[28] Li, X.N, Liu, Z.Y, Luo,H.J, Ma, K, Xiao, B.L, Wang, D, Ma, Z.Y. (2023). Enhancing strength-ductility synergy of graphene/Al-Cu-Mg composites via forming MgAl2O4@graphene complex structure, Compos. Commun. 43, 101737. https://doi.org/10.1016/j.coco.2023.101737.

[29] Zhang, Z, Nie, K.B, Deng, K.K, Xu, C. (2024). Preparation of low-cost, high-strength and fast-dissolving (MgO-Al3Fe)/AZ91 magnesium matrix composites using a novel in-situ reaction, Compos. Commun. 49, 101986. https://doi.org/10.1016/j.coco.2024.101986.

[30] Chankitmunkong, S, Eskin, D.G, Limmaneevichitr, C. (2020). Structure refinement, mechanical properties and feasibility of deformation of hypereutectic Al-Fe-Zr and Al-Ni-Zr alloys subjected to ultrasonic melt processing, Mater Sci Eng, A788, 139567. https://doi.org/10.1016/j.msea.2020.139567.

[31] Pu, B.W, Lin, X.B, Li, B.W, Chen, X.F, He, C.N, Zhao, N.Q. (2020). Effect of SiC nanoparticles on the precipitation behavior and mechanical properties of 7075Al alloy, J. Mater. Sci. 55, 6145–6160. https://doi.org/10.1007/s10853-020-04381-4.

[32] Chen, Y.Y, Nie, J.F, Wang, F, Yang, H.B, Wu, C.C, Liu, X.F, Zhao, Y.H. (2020). Revealing hetero-deformation induced (HDI) stress strengthening effect in laminated Al-(TiB2+TiC)p/6063 composites prepared by accumulative roll bonding, J. Alloy Compd. 815, 152285. https://doi.org/10.1016/j.jallcom.2019.152285.

[33] Sharma, A, Morisada, Y, Ushioda, K, Fujii, H. (2024). Elucidation of the factors controlling interface decohesion and particle fracture in a friction stir alloyed Al–Fe alloy system, Materialia 34, 102066. https://doi.org/10.1016/j.mtla.2024.102066.

[34] Zhang, Q, Xiao, B.L, Wang, W.G, Ma, Z.Y. (2012). Reactive mechanism and mechanical properties of in situ composites fabricated from an Al-TiO2 system by friction stir processing. Acta Mater. 60, 7090–7103. https://doi.org/10.1016/j.actamat.2012.09.016.

[35] Fribourg, G, Brechet, Y, Deschamps, A, Simar, A. (2011). Microstructure-based modelling of isotropic and kinematic strain hardening in a precipitation-hardened aluminium alloy, Acta Mater. 59, 3621–3635. https://doi.org/10.1016/j.actamat.2011.02.035.

[36] Xu, Z.H, Zhang, X, Zhao, N.Q, He, C.N. (2020). Synergistic strengthening effect of in-situ synthesized WC1-x nanoparticles and graphene nanosheets in copper matrix composites, Compos. Appl. Sci. Manuf. 133 , 105891. https://doi.org/10.1016/j.compositesa.2020.105891.

[37] Song, X.Y, Gao, M.Q, Yang, B.W, Guan, R.G. (2022). Modification and refinement of Fe-containing phases, mechanical properties and strengthening mechanisms in Al–Fe alloys via Cr alloying and continuous rheo-extrusion, Mater Sci Eng, A 850, 143557. https://doi.org/10.1016/j.msea.2022.143557.

[38] Lan, X.Y, Zhang, Y.P, Li, K, Hu, B, Wang, J, Lu, Q, Wen, J.Y, Zhang, X, Du,Y. (2025). Investigation into the correlation between composition, microstructure, and mechanical properties of Al-xFe-(6-x)Mn alloys, J. Alloy Compd. 1036, 181455. https://doi.org/10.1016/j.jallcom.2025.181455.

[39] Zhao, Q.R, Qian, Z, Cui, X.L, Wu, Y.Y, Lu, X.F. (2015). Optimizing microstructures of dilute Al-Fe-Si alloys designed with enhanced electrical conductivity and tensile strength, J. Alloy Compd. 650, 768–776. http://dx.doi.org/10.1016/j.jallcom.2015.08.052.

Cover Image
Downloads
Published
2026-03-11
Issue
Vol. 2 No. 1 (2026)
Section
Articles
License

Copyright (c) 2026 Hao Lian, Wenlong Yu, Zhiming SHI (Author)

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

How to Cite

The Al2O3 particle reinforced Al-Fe composites fabricated through an in-situ reaction of Fe2O3 powders in Al melts. (2026). Energy & Environment Management, 2(1), 1-16. https://doi.org/10.63333/eem.v2n11

Similar Articles

You may also start an advanced similarity search for this article.

Most read articles by the same author(s)