Fe–Al–Si alloys have been previously reported as an interesting alternative to common high-temperature materials. This work aimed to improve the properties of FeAl20Si20 alloy (in wt.%) by the application of powder metallurgy process consisting of ultrahigh-energy mechanical alloying and spark plasma sintering. The material consisted of Fe3Si, FeSi, and Fe3Al2Si3 phases. It was found that the alloy exhibits an anomalous behaviour of yield strength and ultimate compressive strength around 500 °C, reaching approximately 1100 and 1500 MPa, respectively. The results also demonstrated exceptional wear resistance, oxidation resistance, and corrosion resistance in water-based electrolytes. The tested manufacturing process enabled the fracture toughness to be increased ca. 10 times compared to the cast alloy of the same composition. Due to its unique properties, the material could be applicable in the automotive industry for the manufacture of exhaust valves, for wear parts, and probably as a material for selected aggressive chemical environments.

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This work describes properties of newly developed Fe-Al-Si alloy for high-temperature applications. This alloy is a material composed of FeAl, FeSi a Fe3Al2Si3 intermetallic compounds, which was prepared by powder metallurgy using mechanical alloying and spark plasma sintering. The oxidation resistance at the temperatures of 800 and 1000 °C was described, as well as the mechanical properties up to 700 °C. During oxidation, the alloy covers by aluminium oxide layer, which protects it against further oxidation. Concerning the mechanical properties, the yield strength and ultimate compressive strength increase in the temperature interval of 400 -500 °C.