Low-cost ferro–nickel alloy was fabricated by recycling high-iron red mud and laterite nickel ore with coke reductant. Na2CO3 and CaO additives facilitated the reduction of fayalite and nickel ferrite. The phase analysis, morphology change and mechanical performance were determined by X-ray diffraction, optical emission spectrometry and scanning electron microscopy with energy dispersive spectroscopy. Microstructural characterizations indicated that the ferro–nickel alloy consisted of ledeburite or martensite matrix, white cementite and graphite nodules. The addition of sodium carbonate intensified the reduction in metal oxides and improved the ferro-nickel alloy grain growth. The Ni and Cr from laterite ores led to austenite phase transition to martensite during cooling and improved the alloy hardenability. This work provides an economic and easy route to produce high-performance ferro-nickel alloy by recycling high-iron red mud.
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Wang et al. (2021) studied this question.