Abstract AlCoCrFeNi alloys are widely studied due to the combination of high strength in a wide temperature range, good corrosion and wear resistance, but they typically present low ductility. Due to this limited ductility, traditional bulk fabrication processes that involve forming are difficult, and casting processes are also non-ideal due to pronounced segregation and coarse microstructure. Therefore, both the selective laser melting and the powder metallurgy are more promising routes for this alloy, both of these use powder as starting material. This work aimed to produce powder of Al20Co20Cr20Fe20Ni20 alloy by gas atomization and to perform its detailed characterization.The results show that the powder is mainly spherical, which resulted in good flowability. Most of the powder (62%) has a size smaller than 75µm, and microscopy analyses confirmed that a B2 dendritic microstructure was formed, with A2 cuboidal precipitates.

An alternative route to obtain bulk metallic glasses is by consolidation of metallic glass powders by deforming these materials in the temperature interval between the crystallization temperature and the glass transition temperature, where the material flows with a reduced viscosity. In the present work, bulk parts of the Fe43.2Co28.8B19.2Si4.8Nb4 alloy were produced by hot-pressing gas-atomized powders (GAP) under different uniaxial pressures. Different microstructural analysis revealed that the initial powder as well as the consolidated parts were mostly amorphous, with similar transformation temperatures, showing that bulk samples of this alloy can be produced by conformation in the supercooled liquid region. The sample conformed under the highest pressure (1GPa) exhibited the highest relative density of 96.1±0.5%. These results show that hot pressing of Fe-based gas-atomized powders is a promising route for producing Fe-based bulk metallic glasses.