Fabrication of iron-rich Fe-Al intermetallics using the wire-arc additive manufacturing process

A wire-arc additive manufacturing (WAAM) system is used to fabricate iron rich Fe-Al intermetallics with 25 at% aluminum content. The alloy is produced in situ through controlled addition of the elemental iron and aluminum components into the welding process. The properties of the fabricated material are assessed using optical microstructure analysis, hardness testing, tensile testing, X-ray diffraction phase characterization and electron dispersive spectrometry. It is shown that the WAAM system is capable of producing iron rich Fe-Al intermetallics with higher yield strength and similar room temperature ductility when compared to equivalent materials produced using powder metallurgy.