Realization of a Novel FeSiAlCuSn Multicomponent Alloy and Characterization of Intermetallic Phases Formed at Different Temperatures During Cooling

Ferrosilicon (FeSi) is a commercially important material with multiple uses in metallurgical processes. Recently, in an attempt to reduce the carbon impact of the FeSi production process, researchers have proposed using recycled Si recovered from electronic waste in the production of FeSi. However, Si recovered from electronic waste usually contains Al, Cu, and Sn as impurities. Hence, FeSi alloys produced with recycled Si from electronic waste may contain all these elements in varying proportions. Al, Cu, and Sn have been explored as alloying elements to produce alloys with Fe. FeSiAl alloys have also been studied recently for their superior properties. In this work, a multicomponent FeSiAlCuSn alloy is produced, and the phases formed at different temperatures are analyzed using different phase identification techniques. We also analyze the hardness of the multicomponent alloy to find any deviation from the standard FeSi alloy without the additional alloying elements. Understanding the phases and the composition of such alloys may help design future multi-component or high-entropy alloys involving Fe, Si, Al, Cu, and Sn for specific applications.