Fast consolidation of a nanocrystalline Al2O3 reinforced 3.7Fe0.54Cr0.18Al0.26Si0.016 composite from mechanical synthesized powder through pulsed current activated heating

► Nanopowders of Fe0.54Cr0.18Al0.26Si0.016 and Al2O3 were fabricated from Fe2O3, Cr, Si, and Al powders using high-energy ball milling. ► Densification of a nanostructured 3.7Fe0.54Cr0.18Al0.26Si0.016-Al2O3 composite prepared from mechanically alloyed powders was accomplished using the PCASM. ► Complete densification was achieved within a processing time of 3 min under an applied pressure of 80 MPa and an induced current. ► The average grain sizes of the Fe0.54Cr0.18Al0.26Si0.016 alloy and Al2O3 prepared through PCASM were approximately 22 nm and 48 nm, respectively, and the average hardness value was 450 kg/mm2.