Pure FeAl intermetallic compound was prepared by the field-activated combustion synthesis (FACS) process. Effects of compaction pressure (150, 250, and 350 MPa) and particle size (-25, -80, and -325 mesh) on the characteristics of products were investigated. As the compaction pressure and electric field increased, the combustion temperature and velocity increased. The influences of different current application methods on the reaction in this system were investigated. In the absence of an electric field, the reaction could not sustain a steady combustion wave and was not completed. The reaction products were characterized by X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray spectroscopy to determine the structures and compositions. (C) 2000 Elsevier Science Ltd. All rights reserved.