Powder metallurgy Al–6Cr–2Fe–1Ti alloy prepared by melt atomisation and hot ultra-high pressure compaction

Al6Cr2Fe1Ti alloy was prepared by melt atomisation into rapidly solidified powder. The powder was compacted using uniaxial hot compression at an ultra-high pressure (6 GPa). The samples were pressed at 300, 400 and 500 °C. The structure, mechanical properties and thermal stability were examined and compared with those of the commercially available Al12Si1Cu1Mg1Ni casting alloy, which is considered thermally stable. It was shown that the hot compression at ultra-high pressure results in a compact and pore-free material with excellent mechanical properties. The elevated pressing temperatures were found to be effective at increasing the mechanical stability after applying the ultra-high pressure. The results of thermal stability testing revealed that the mechanical properties do not change significantly at high temperature, even after 100 h of annealing at 400 °C. In addition, the Al6Cr2Fe1Ti alloy exhibited very good creep resistance. A comparison between the commercial Al12Si1Cu1Mg1Ni alloy and the powder metallurgy alloy shows that this alloy has significantly better mechanical properties and thermal stability.