Spark plasma sintering as a reactive sintering tool for the preparation of surface-tailored Fe–FeAl2O4–Al2O3 nanocomposites

Al1.86Fe0.14O3 powders were partially or totally reduced in H2. The fully reduced Fe–Al2O3 nanocomposite powder was sintered by spark plasma sintering (SPS) without any reaction taking place. For the other powders, the SPS induced the formation of FeAl2O4 and sometimes Fe. The most severe reducing conditions were found at the surface of the materials, producing nanocomposites with a surface layer composition and microstructure different to those of the core. This in situ formed composite layer confers a higher hardness and fracture strength.