Reaction products and their solidification process of the plasma sprayed Fe2O3-Al composite powders

► The reaction products of Fe2O3-Al composite powders in plasma flame were Fe-Al-O ceramic melt. ► FeAl2O4, Al2O3 and FeAl were formed by non-equilibrium solidification of Fe-Al-O ceramic melt. ► The formation of Fe was dependent on the component distribution and reaction kinetics process of each composite particle. ► Fe rich hercynite solid solution (HSS) nucleated and grew preferentially, and then Al rich HSS grew.