Hydrogen-based direct reduction (HyDR) of iron ores has attracted immense attention and is considered a forerunner technology for sustainable ironmaking. It has a high potential to mitigate CO ₂ emissions in the steel industry, which accounts today for ~ 8–10% of all global CO ₂ emissions. Direct reduction produces highly porous sponge iron via natural-gas-based or gasified-coal-based reducing agents that contain hydrogen and organic molecules. Commercial technologies usually operate at elevated pressure, e.g., the MIDREX process at 2 bar and the HyL/Energiron process at 6–8 bar. However, the impact of H ₂ pressure on reduction kinetics and microstructure evolution of hematite pellets during hydrogen-based direct reduction has not been well understood. Here, we present a study about the influence of H ₂ pressure on the reduction kinetics of hematite pellets with pure H ₂ at 700 °C at various pressures, i.e., 1, 10, and 100 bar under static gas exposure, and 1.3 and 50 bar under dynamic gas exposure. The microstructure of the reduced pellets was characterized by combining X-ray diffraction and scanning electron microscopy equipped with electron backscatter diffraction. The results provide new insights into the critical role of H ₂ pressure in the hydrogen-based direct reduction process and establish a direction for future furnace design and process optimization. Graphical Abstract: (Figure presented.)

We combined experimental investigations and theoretical calculations to unveil an abnormal magnetic behavior caused by addition of the nonmagnetic element Cu in face-centered-cubic FeNiCoMn-based high-entropy alloys (HEAs). Upon Cu addition, the probed HEAs show an increase of both Curie temperature and saturation magnetization in as-cast and homogenized states. Specifically, the saturation magnetization of the as-cast HEAs at room temperature increases by 77% and 177% at a Cu content of 11 and 20 at. %, respectively, compared to the as-cast equiatomic FeNiCoMn HEA without Cu. The increase in saturation magnetization of the as-cast HEAs is associated with the formation of an Fe-Co rich phase in the dendritic regions. For the homogenized HEAs, the magnetic state at room temperature transforms from paramagnetism to ferromagnetism after 20 at. % Cu addition. The increase of the saturation magnetization and Curie temperature cannot be adequately explained by the formation of Cu enriched zones according to atom probe tomography analysis. Ab initio calculations suggest Cu plays a pivotal role in the stabilization of a ferromagnetic ordering of Fe, and reveal an increase of the Curie temperature caused by Cu addition which agrees well with the experimental results. The underlying mechanism behind this phenomenon lies in a combined change in unit-cell volume and chemical composition and the related energetic stabilization of the magnetic ordering upon Cu alloying as revealed by theoretical calculations. Thus, the work unveils the mechanisms responsible for the Cu effect on the magnetic properties of FeNiCoMn HEAs, and suggests that nonmagnetic elements are also crucial to tune and improve magnetic properties of HEAs.