Polymer atomization of iron aluminide

A method of atomizing a reactive alloy melt (iron aluminide) with a polymer fluid was investigated. Prototype powder samples were prepared using this method, and the resultant powder chemistry and morphology were compared to water and gas-atomized powders. The advantages of this method over gas and water atomization along with some properties of an iron aluminum alloy powder prepared in this way were described. Some powder was further roll compacted into green sheets, and densified using a thermo-mechanical process with a series of rolling and annealing steps. The properties of the densified sheets were examined and compared with the properties of the sheets made with water and gas-atomized powders.