Preparation and properties of Al-Fe3O4 casting functional powder of novel iron-based composite

The cast-penetration process is a widely utilized technique for fabricating metal matrix composites. Al-Fe₃O₄ powder has emerged as a novel functional material for casting applications. This study focuses on investigating the reaction characteristics, underlying mechanisms, and the influence of process parameters on exothermic properties. Notably, the reaction products are significantly affected by varying atmospheric conditions. The Al-Fe₃O₄ casting functional powder undergoes six temperature nodes during the heating process from 20 °C to 1300 °C. By precisely controlling the powder parameters, the reaction temperature can be adjusted within a broad range (600 °C–900 °C), while the exothermic energy output can be regulated between 200 J/g and 1300 J/g. Al-Fe₃O₄ casting functional powder enables innovative casting applications through its exothermic reaction, which generates Fe and Al₂O₃ while releasing significant heat. This released heat effectively elevates the temperature at the ZTA and substrate interfaces, thereby promoting metallurgical bonding and forming an optimized flexible interface layer that significantly enhances the overall performance of the composite material.