The effect on the mechanical properties at room temperature of Li and Ag additions to the Fe–Al (40 at.%)-based alloy produced by conventional casting were evaluated in this work. Alloying elements were added into a previously molted Fe–(40 at.%) aluminum-based alloy, stirred, and then cast into sand molds to directly produce tensile specimens. To determine the mechanical properties, tensile tests and hardness measurements were performed. The additions of both Ag and Li showed an increase in ductility and tensile strength of the intermetallic alloys. In addition, hardness was substantially increased with the Li addition. Lithium additions promoted a solid solution hardening, whereas 3 at.% of Ag additions promoted ductility due to a microstructural modification and to the formation of a soft Ag3Al phase. Characterization by both optical and electronic microscopy, energy dispersive spectroscopy microanalysis, and x-ray diffraction supported the mechanical characterization.

The iron aluminide Fe3Al has been successfully processed by selective laser melting (SLM) and laser metal deposition (LMD). Process parameters have been determined by which defect free and dense (>99.5%) samples were produced. However, due to the low thermal conductivity of Fe3Al, preheating the substrate to 200 °C was necessary to prevent cracking during cooling. Microstructural characterization by electron backscatter diffraction (EBSD) showed that in spite of the high cooling rates large elongated grains grew in the building direction, more distinctive for SLM than for LMD. These grains show a continuous change in the crystallographic orientation. Evaluation of the compressive flow stress showed that the anisotropic microstructure results in anisotropic mechanical properties, depending whether the samples are loaded in building direction or perpendicular to it. The alloy shows a very high strength up to 600 °C and – concerning the coarse microstructure – becomes ductile already at low temperatures.