Provided is a method of manufacturing a crystalline aluminum-iron-silicon alloy, and optionally an automotive component comprising the same, comprising forming a composite ingot including a plurality of crystalline phases by melting aluminum, iron, and silicon raw materials in an inert environment to form a substantially homogenous melt, subsequently solidifying the melt, and annealing the ingot under vacuum by heating at a temperature in the range of 850 C. to 1000 C. yield an annealed crystalline ingot wherein the predominant crystalline phase is FCC Al.sub.3Fe.sub.2Si. The raw materials can further include one or more additives such as zinc, zirconium, tin, and chromium. Melting can occur above the FCC Al.sub.3Fe.sub.2Si crystalline phase melting point, or at a temperature of about 1100 C. to about 1400 C. Annealing can occur under vacuum conditions.

Embodiments disclosed herein relate to the production of amorphous metals having compositions of iron, chromium, molybdenum, carbon and boron for usage in additive manufacturing, such as in layer-by-layer deposition to produce multi-functional parts. Such parts demonstrate ultra-high strength without sacrificing toughness and also maintain the amorphous structure of the materials during and after manufacturing processes. Two additive manufacturing techniques are provided: (1) the complete melting of amorphous powder and re-solidifying to amorphous structure to eliminate the formation of crystalline structure therein by controlling a heating source power and cooling rate without affecting previous deposited layers; and (2) partial melting of the outer surface of the amorphous powder, and solidifying powder particles with each-other without undergoing a complete melting stage. Amorphous alloy compositions have oxygen impurities in low concentration levels to optimize glass forming ability (GFA). Specific techniques of additive manufacturing include those based on lasers, electron beams and ultrasonic sources.

Wear resistant articles are described herein which, in some embodiments, mitigate CTE differences between wear resistant components and metallic substrates. In one aspect, an article comprises a layer of sintered cemented carbide bonded to a layer of iron-based alloy via a metal-matrix composite bonding layer, wherein coefficients of thermal expansion (CTE) of the sintered cemented carbide layer, metal matrix composite bonding layer, and iron-based alloy layer satisfy the relation:

[00001]$x=\frac{\left(.Math.C.Math..Math.T.Math..Math.E.Math..Math.\mathrm{WC}-C.Math..Math.T.Math..Math.E.Math..Math.M.Math..Math.M.Math..Math.C.Math.\right)}{\left(.Math.C.Math..Math.T.Math..Math.E.Math..Math.M.Math..Math.M.Math..Math.C-C.Math..Math.T.Math..Math.E.Math..Math.\mathrm{Fe}.Math.\right)}$

wherein 0.5x2 and CTE WC, CTE MMC and CTE Fe are the CTE values for the sintered cemented carbide, metal matrix composite, and iron-based a

Wear resistant articles are described herein which, in some embodiments, mitigate CTE differences between wear resistant components and metallic substrates. In one aspect, an article comprises a layer of sintered cemented carbide bonded to a layer of iron-based alloy via a metal-matrix composite bonding layer, wherein coefficients of thermal expansion (CTE) of the sintered cemented carbide layer, metal matrix composite bonding layer, and iron-based alloy layer satisfy the relation:

[00001]$x=\frac{\left(.Math.C.Math..Math.T.Math..Math.E.Math..Math.\mathrm{WC}-C.Math..Math.T.Math..Math.E.Math..Math.M.Math..Math.M.Math..Math.C.Math.\right)}{\left(.Math.C.Math..Math.T.Math..Math.E.Math..Math.M.Math..Math.M.Math..Math.C-C.Math..Math.T.Math..Math.E.Math..Math.\mathrm{Fe}.Math.\right)}$

wherein 0.5x2 and CTE WC, CTE MMC and CTE Fe are the CTE values for the sintered cemented carbide, metal matrix composite, and iron-based a

Disclosed are a high strength-ductility matched oxide-particles dispersion steel, a preparation method and application thereof, belonging to the technical field of novel structural materials. The high strength-ductility matched oxide-particles dispersion steel comprises the following components in percentage by mass: chromium (Cr) 11.0-13.0 percent (%), tungsten (W) 1.0-2.0%, vanadium (V) 0.1-0.2%, yttrium (Y) 0.3-0.4%, oxygen (O) 0.05-0.15%, silicon (Si) 1.5-2.5%, carbon (C) 0.0016%, with iron (Fe) and unavoidable impurities accounting for a rest. The high strength-ductility matched oxide-particles dispersion steel in the present application is prepared, using a powder metallurgical preparation method, by introducing high-content of silicon elements and introducing high-density oxide particles with a complete core-shell structure using a specific heat treatment regime.

An example composition may include a plurality of grains including an iron nitride phase. The plurality of grains may have an average grain size between about 10 nm and about 200 nm. An example technique may include treating a composition including a plurality of grains including an iron-based phase to adjust an average grain size of the plurality of grains to between about 20 nm and about 100 nm. The example technique may include nitriding the plurality of grains to form or grow an iron nitride phase.

An inoculant for the manufacture of cast iron with spheroidal graphite is disclosed, the inoculant has a particulate ferrosilicon alloy having between 40 and 80% by weight of Si; 0.02-8% by weight of Ca; 0-5% by weight of Sr; 0-12% by weight of Ba; 0-15% by weight of rare earth metal; 0-5% by weight of Mg; 0.05-5% by weight of Al; 0-10% by weight of Mn; 0-10% by weight of Ti; 0-10 by weight of Zr; the balance being Fe and incidental impurities in the ordinary amount, wherein the inoculant additionally contains, by weight, based on the total weight of inoculant: 0.1 to 15% of particulate Bi.sub.2S.sub.3, and optionally between 0.1 and 15% of particulate Bi.sub.2O.sub.3, and/or between 0.1 and 15% of particulate Sb.sub.2O.sub.3, and/or between 0.1 and 15% of particulate Sb.sub.2S.sub.3, and/or between 0.1 and 5% of particulate Fe.sub.3O.sub.4, Fe.sub.2O.sub.3, FeO, or a mixture thereof, and/or between 0.1 and 5% of one or more of particulate FeS, FeS.sub.2, Fe.sub.3S.sub.4, or a mixture thereof, a method for producing such inoculant and use of such inoculant.

It is an object of the present disclosure to produce a soft magnetic material having high saturation magnetization by heat-treating a Fe-based amorphous alloy, without needing the control of the atmosphere. The present disclosure provides a method for producing a soft magnetic material, including heat treating a Fe-based amorphous alloy in a state in which the alloy is wrapped with a sheet comprising one or more substances having a standard Gibbs energy of formation of an oxide thereof that is larger in a negative direction than Fe, to form a crystal phase.

The invention discloses a centimeter-level high-strength iron-based bulk amorphous alloy and novel copper mold casting method thereof; the molecular formula thereof is Fe.sub.44-xCo.sub.6Cr.sub.15Mo.sub.14C.sub.15B.sub.6Tm.sub.x, wherein x represents the atomic percent of corresponding alloy elements and 0x6; the novel copper mold casting method comprising: directly cooling a copper mold with cooling water under negative pressure through electric arc melting to obtain an amorphous alloy ingot; the alloy has the remarkable characteristics of high amorphous forming ability, high strength and high hardness, by the conventional casting, the maximum critical diameter can be 10 mm, the highest strength can be 4295 Mpa, and the highest Vickers hardness can be 1220 Hv; meanwhile, the alloy has obvious spinning glass behavior at low temperature; the preparation method has low cooling rate, is free from the limitation of mold diameter, and can directly obtain the amorphous alloy ingot, the cost is reduced, and the maximum diameter of the amorphous alloy ingot is 16.52 mm; and by the preparation method, the amorphous forming ability of the bulk amorphous alloy can be determined more accurately.

An amorphous alloy particle is an amorphous alloy particle formed of an iron-based alloy, and the particle contains a grain boundary layer.