Nanostructure of surface formed by vacancy clustering in FeAl

In B2-type FeAl, supersaturated vacancies retained upon rapidly quenching are absorbed near surface during an aging treatment, being agglomerated into nano- to meso-clusters through the absorption process. Eventually, surface morphology is self-patterned in nano-order by the vacancy clustering. If FeAl was not quenched from high temperature or plastic strain remained near surface, the surface self-patterning never occurs, indicating that the change in surface morphology is caused by the clustering of supersaturated vacancies. The clusters have specific shape with cluster surfaces faceted toward {100} planes. Thus, the shape of the clusters formed near surface is controllable by changing surface orientation. Vacancy cluster size and its distribution density can be also controlled by varying the concentration of supersaturated vacancies and/or the clustering condition. These indicate that the vacancy clustering is a unique process to efficiently pattern the surfaces of metals, alloys and intermetallics in nano-scale.