Synthesis and characterization of iron aluminide nanoparticles by DC thermal plasma jet

Intermetallic iron aluminide alloy nanoparticles were synthesized by non-transferred DC plasma spray torch at atmospheric pressure. These powder particles were characterized by vibrating sample magnetometer (VSM), X-ray diffraction (XRD), environmental scanning electron microscopy (ESEM), laser scattering particle size distribution analyzer, energy dispersive X-ray spectra (EDX) and thermo gravimetric-differential thermal analysis (TG/DTA) studies and the results are discussed. Commercially available iron and aluminium powders in the size range between 40 and 100 μm were ball milled with suitable ratio (Fe-85% and Al-15%) by weight to form a iron–aluminium blende; this was used as feed stock to synthesize iron aluminide nanoparticles. These nanoparticles particles were spherical in shape and black in colour, with the size range between 30 and 70 nm observed by ESEM. It is seen that the powders processed at higher power levels (15.3 kW) have more number of single spherical nanoparticles than powders processed at lower power levels (9.8 kW). The formation of iron aluminide nanoparticles is confirmed by XRD analysis and an exothermic reaction by DTA studies.