Mechanical and magnetic properties of γ-Ni-xFe/Al2O3 composites

Ultra-fine grained γ-Ni-xFe (x = 20, 50, and 64 (nominal)) dispersed Al2O3-matrix composites were fabricated by a mechano-chemical process plus hot-pressing, and their mechanical and magnetic properties were explored. The results indicated that all composites incorporated with different γ-Ni-xFe alloys possessed high densities (relative density D ⩾ 98%) and sub-micrometer-sized matrix dispersed with γ-Ni-xFe particles of sizes below ∼500 nm. As compared to other two composite systems, γ-Ni-20Fe/Al2O3 had finer microstructures and displayed superior fracture toughness and strength. In high iron-contained γ-Ni-64Fe/Al2O3 composite undesired FeAl2O4 phase formed on the matrix grain boundaries, which is mainly responsible for its inferior mechanical properties. Although Young's modulus and hardness of Ni-20Fe/Al2O3 composite system decreased, its fracture toughness increased monotonously with increasing the alloy content in the composition range investigated. Moreover, incorporation of ferromagnetic γ-Ni-xFe particles led all the composite systems to display ferromagnetism with their saturation magnetization increasing almost linearly with increasing alloy content. In addition, experiments showed that their ferromagnetism had high thermal stability (Tc = ∼580 °C), no obvious magnetism degradation and magnetic interactions of the alloys with the matrix being observed. The combination of good mechanical properties with excellent magnetic performance would make this material be very valuable in industry.