Synthesis and characterization of Al₈₂Fe₁₄Ni₄ bulk metallic glass via mechanical alloying and high-pressure consolidation

Al-based bulk metallic glasses (BMGs) have attracted significant research interest due to their enhanced mechanical and functional properties compared to conventional crystalline materials, making them promising candidates for structural and biomedical applications. In this study, the Al₈₂Fe₁₄Ni₄ alloy was processed through a combination of mechanical alloying and high-pressure treatment to identify the optimal parameters for BMG synthesis. Elemental powders were milled for 80 h in a high-energy vibratory mill, followed by consolidation under varying pressure and temperature conditions. Structural and mechanical characterization was carried out using X-ray diffraction (XRD), Vickers microhardness testing, and vibrating sample magnetometry (VSM). The sample subjected to 80 h of milling and subsequently treated at 7.7 GPa and ∼25°C for 10 min yielded the most promising results. XRD analysis revealed an amorphous halo consistent with a glassy structure, indicating that this condition produced the closest approximation to a BMG. This sample achieved a microhardness of 606 HV. Additionally, VSM measurements showed an increase in saturation magnetization from 0.57 to 0.63 emu/g alongside a high coercivity of 201.24 Oe, classifying the material as a hard magnetic material. These findings suggest that the combination of mechanical alloying and high-pressure treatment promotes structural changes toward an amorphous configuration, enhancing both mechanical and magnetic properties. The combination of these two processing routes represents a promising approach for the synthesis of Al₈₂Fe₁₄Ni₄-based BMGs.