In this study, dense bulk iron nitrides (FexN) were synthesized for the first time ever using spark plasma sintering (SPS) of FexN powders. The Fe4N phase of iron nitride in particular has significant potential to serve as a new soft magnetic material in both transformer and inductor cores and electrical machines. The density of SPSed FexN increased with SPS temperature and pressure. The microstructure of the consolidated bulk FexN was characterized with X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and superconducting quantum interference device (SQUID) magnetometry. XRD revealed a primary phase of Fe4N with secondary phases of Fe3N and metallic iron. Finite element analysis (FEA) was also applied to investigate and explain localized heating and temperature distribution during SPS. The effects of processing on interface bonding formation and phase evolution were investigated and discussed in detail to provide insight into fundamental phenomena and microstructural evolution in SPSed FexN.
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