Plasma spraying was used to produce sheets of FeAl-based iron aluminide alloy with densities of 90percent or higher. Sheets of different thicknesses were produced by varying the plasma spray parameters, substrate dimensions, and surface roughness of the substrate. Thermomechanical processing steps were used to convert plasma-sprayed sheets to full density foils of 0.2 mm (0.008 in.) thickness. Good agreement in tensile properties at room temperature and 750 deg C was observed between the foils produced by plasma spraying and other methods. This paper describes the microstructure, microhardness, and tensile properties for the foils produced from the plasma-sprayed sheets of an FeAl-based alloy.
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