An Fe/FeAl₂O₄ composite was prepared with Fe-Fe₂O₃-Al₂O₃ powder by a hot press sintering method. The mass ratio was 6:1:2, sintering pressure was 30 MPa, and holding time was 120 min. The raw materials for the powder particles were respectively 1 µm (Fe), 0.5 µm (Fe₂O₃), and 1 µm (Al₂O₃) in diameter. The effect of sintering temperature on the microstructure and mechanical properties of Fe/FeAl₂O₄ composite was studied. The results showed that Fe/FeAl₂O₄ composite was formed by in situ reaction at 1300 °C–1500 °C. With the increased sintering temperature, the microstructure and mechanical properties of the Fe/FeAl₂O₄ composite showed a change law that initially became better and then became worse. The best microstructure and optimal mechanical properties were obtained at 1400 °C. At this temperature, the grain size of Fe and FeAl₂O₄ phases in Fe/FeAl₂O₄ composite was uniform, the relative density was 96.7%, and the Vickers hardness and bending strength were 1.88 GPa and 280.0 MPa, respectively. The wettability between Fe and FeAl₂O₄ was enhanced with increased sintering temperature. And then the densification process was accelerated. Finally, the microstructure and mechanical properties of the Fe/FeAl₂O₄ composite were improved.

The Fe/FeAl₂O₄ cermet was prepared with Fe-Fe₂O₃-Al₂O₃ powder by a hot press sintering method at 1400 °C. The raw materials for the powder particles were respectively 2 µm (Fe), 0.5 µm (Fe₂O₃), and 0.5 µm (Al₂O₃) in diameter, the sintering pressure was 30 MPa, and the holding time was 120 min. The effects of different Fe mass ratios on the microstructure and mechanical properties of Fe/FeAl₂O₄ cermet were studied. The results showed that a new ceramic phase FeAl₂O₄ could be formed by an in situ reaction during the hot press sintering. When the Fe mass ratio was increased, the microstructure and mechanical properties of the Fe/FeAl₂O₄ cermet showed a change law that initially became better and then became worse. The best microstructure and mechanical properties were obtained in the S2 sample, where the mass ratio of Fe-Fe₂O₃-Al₂O₃ was 6:1:2. In this Fe mass ratio, the relative density was about 94%, and the Vickers hardness and bending strength were 1.21 GPa and 210.0 MPa, respectively. The reaction mechanism of Fe in the preparation process was the in situ synthesis reaction of FeAl₂O₄ and the diffusion reaction of Fe to FeAl₂O₄ grains. The increase of the Fe mass ratio improved the wettability of Fe and FeAl₂O₄, which increased the diffusion rate of Fe to FeAl₂O₄ grains, which increased the influence on the structure of FeAl₂O₄.