FeSi-NiAl composite as a future tool material

Composite materials based on NiAl matrix and FeSi reinforcement are tested as potential tool materials in this work. The components (FeSi, NiAl) were prepared by mechanical alloying separately, blended and consolidated by spark plasma sintering method. The results showed that the composite blend can be successfully sintered at 1000 °C. Thermodynamic calculations were performed in SW Thermo-Calc, ver. 2019a for obtaining the phase diagrams of the studied systems. The composite has the hardness almost comparable with the heat-treated cold work tool steels. The hardness increases with the growing amount of silicide in the mixture. The same trend can be slightly visible also in wear resistance and the results nearly reach the performance of high-grade cold-work tool steels but having lower friction coefficient. The ultimate compressive strength reached values of 1830–2640 MPa, depending on chemical composition. The result indicate that these materials could reach the performance of the high grades of tool steel, but without the need for any heat treatment, which makes them to be a really promising eco-friendly alternative. •New FeSi-NiAl composite successfully manufactured by powder metallurgy.•Metastable phase composition, but no significant changes during processing.•Hardness and wear resistance comparable to tool steel, no heat treatment needed.•Eco-friendly alternative to cold-work tool steel.