An ultrasonic device was designed to fabricate relatively small (about 0.7 kg) vacuum chill castings of FeAl-based alloys with improved microstructure. The influence of ultrasound on the solidification microstructure of the Fe-40 at.% Al based castings was investigated. The subsequent hot-rolling of such an as-cast alloy was made using a special stainless steel bandage of the casting. This effectively prevents fraying and cracking caused by the thermal shock arising at the surface of the hot casting, when it comes in contact with a cold roller. The efficiency of ultrasonic vacuum casting, based on the influence of the acoustic cavitation on the solidification of the melt, is manifested by a refined microstructure of the prepared iron aluminides Fe-40 at.% Al with addition of C or Zr and B. First results of improved mechanical properties of these alloys are presented and discussed.