The effect of Ce addition on the microstructure of carbon-alloyed Fe₃Al-based intermetallic has been studied. Three different alloys of composition, Fe–18.5Al–3.6C, Fe–20.0Al–2.0C and Fe–19.2Al–3.3C–0.07Ce (in at%), were prepared by electroslag remelting process. Their microstructures were characterized using optical and scanning electron microscopies. Stereological methods were utilized to understand the observed microstructures. All the alloys exhibited a typical two-phase microstructure consisting of Fe₃AlC carbides in an iron aluminide matrix. In the alloy without Ce addition, large bulky carbides were equally distributed throughout the matrix with many smaller precipitates interspersed in between. In the alloy with Ce addition, the carbide grain sizes were finer and uniformly distributed throughout the matrix. The effect of Ce addition on the carbide morphology has been explained based on the known effect of Ce in modifying carbide morphology in cast irons.

The effect of cerium content and thermomechanical processing on structure and properties of Fe–10.5 wt.%Al–0.8 wt%C alloy has been investigated. Alloys were prepared by a combination of air induction melting with flux cover (AIMFC) and electroslag remelting (ESR). The ESR ingots were hot-forged and hotrolled at 1373 K as well as warm-rolled at 923 K and heat-treated. Hot-rolled, warm-rolled and heat treated alloys were examined using optical microscopy, scanning electron microscopy (SEM) and X-ray diffraction to understand the microstructure of these alloys. The ternary, Fe–10.5 wt.%Al–0.8 wt.%C alloy showed the presence of two phases; Fe–Al with bcc structure, and large volume fraction of Fe₃AlC_0.5 precipitates. Addition of cerium to Fe–10.5 wt.%Al–0.8 wt.%C alloy resulted in three phases, the additional phase being small volume fraction of fine cerium oxy-carbide precipitates. Improvement in tensile elongation from 3–6.4% was achieved by increasing the cerium content from 0.01–0.2 wt.% and further improvement in tensile elongation from 6.4–10% was achieved by warm-rolling and heat treatment.