Using the nano Fe powders having 50 nm in diameter, Fe compact bodies were fabricated by injec-tion molding process. The relationship between microstructure and material properties depending on the volume ratio of powder/binder and sintering temperature were characterized by SEM, TEM techniques. In the compact body with the volume percentage ratio of 45(Fe powder) : 55(binder), which was sintered at the relative density was about and the values of volume shrinkage and hardness were about and 242.0 Hv, respec-tively. Using the composition of 50(Fe powder) : 50(binder) and sintered at the values of relative density, volume shrinkage and hardness of Fe sintered bodies were and 152.8 Hv, respectively. They showed brittle fracture mode due to the porous and fine microstructure.

The microstructure and mechanical property of hot-pressed composites with a different temperature for atmosphere changing from H to Ar have been studied. When atmosphere-changed from H to Ar gas at 145, the hot-pressed composite was characterized by inhomogeneous microstructure and low fracture strength. On the contrary, when atmosphere-changed at low temperature of 110 the composite showed more homogeneous microstructure, higher fracture strength and smaller deviation in strength. Based on the thermodynamic consideration and microstructural analysis, it was interpreted that the Cu wetting behavior relating to the formation of CuAlO is probably responsible for strong dependence of microstructure on atmosphere changing temperature. The reason for a strong sensitivity of fracture strength and especially of its deviation to atmosphere changing temperature was explained by the microstructural inhomogeneity and by the role of CuAlO phase on the interfacial bonding strength.

Fe nanopowders were successfully synthesized by plasma arc discharge (PAD) process using Fe rod. The influence of chamber pressure on the microstructure was investigated by means of X-ray Diffraction (XRD), Field Emission Scanning Electron Microscope (FE-SEM), Transmission Electron Microscopy (TEM) and X-ray Photoelectron Spectroscopy (XPS). The prepared particles had nearly spherical shapes and consisted of metallic cores (a-Fe) and oxide shells (FeO), The powder size increased with increasing chamber pressure due to the higher dissolution and ejection rate of H and gas density in the molten metal.