TY - GEN A1 - Ertugrul, Gökhan A1 - Emdadi, Aliakbar A1 - Härtel, Sebastian ED - MacDonald, Eric W. T1 - Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition T2 - Additive manufacturing letters N2 - With a combination of desirable properties such as low density, high specific yield strength, low material cost, and excellent oxidation and corrosion resistance, iron aluminide (Fe-Al) has shown considerable potential to be an alternative to high-alloy chromium steels, and in some cases even nickel-based superalloys, in high-temperature applications. Due to these features, it is especially suitable for the aerospace and automotive industries. Recent advancements indicate an increasing interest in Fe-Al within the additive manufacturing industry, particularly in directed energy deposition (DED) processes. Despite this progress, processing of Fe-Al materials using the laser directed energy deposition (L-DED) has not been sufficiently investigated. In this study, Fe-Al powder material was produced from a commercial Al rod encased in a commercial low alloy-steel tube by a plasma-based ultrasonic atomization eliminating the need to cast an alloy ingot in advance. Subsequently, the produced powder was used in a l-DED process to fabricate an additively manufactured sample. The sample was investigated in terms of mechanical property, microstructure, chemical composition, and phase structure by scanning electron microscope (SEM) / energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), electron backscatter diffraction (EBSD) and microhardness analyses. KW - Iron Aluminides (Fe-Al); Additive Manufacturing; Laser-Directed Energy Deposition (L-DED); Process Chain Plasma Ultrasonic Atomization; Powder; Intermetallic Phase Y1 - 2025 U6 - https://doi.org/10.1016/j.addlet.2025.100313 SN - 2772-3690 VL - 14 SP - 1 EP - 9 PB - Elsevier BV CY - Amsterdam ER -