Skip to main content
SpringerLink
Log in

Microstructure characteristics and mechanical properties of the interface layer of coated steel insert-aluminum bimetals

  • Article
  • Published:
Journal of Materials Research Aims and scope Submit manuscript

Abstract

The effect of aluminizing and Cu electroplating of the steel insert in fabrication of Al-matrix bimetal on the microstructure and mechanical properties of the interface layer was investigated. Compound casting process was used to fabricate Al-matrix bimetals reinforced with coated steel insert. The microstructures at the interface region were studied using light optical and scanning electron microscopes and energy dispersive X-ray spectroscopy. The interfacial shear strengths of the fabricated bimetals were compared using push-out test. The results showed that electroplating with copper and aluminizing of steel insert in aluminum matrix led to significant improvement of metallurgical bonding between the steel and aluminum cast matrix. Cu-coated insert contained a thicker and uniform reaction layer formed at the interface between the steel insert and aluminum matrix compared to aluminized coated insert. The results of push-out tests indicated higher interfacial shear strength for the bimetal with Cu-coated insert despite possessing a larger thickness.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

FIG. 1
FIG. 2
FIG. 3
FIG. 4
FIG. 5
FIG. 6
FIG. 7
FIG. 8
FIG. 9

Similar content being viewed by others

References

  1. J.C. Vaila, M. Peronnet, F. Barbeau, F. Bosselet, and J. Bouix: Interface chemistry in aluminum alloy castings reinforced with iron base insert. Composites, Part A 33, 1417 (2002).

    Article  Google Scholar 

  2. A. Bouayad, C. Gerometta, M. Radouani, and A. Saka: Interface characterization in aluminum alloy casting reinforced with SG iron insert. J. Adv. Res. Mech. Eng. 1, 226 (2010).

    Google Scholar 

  3. K.J.M. Papis, B. Hallstedt, J.F. Löffler, and P.J. Uggowitzer: Interface formation in aluminum–aluminum compound casting. Acta Mater. 56, 3036 (2008).

    Article  CAS  Google Scholar 

  4. E. Hajjari, M. Divandari, S.H. Razavi, T. Homma, and S. Kamado: Microstructure characteristics and mechanical properties of Al 413/Mg joint in compound casting process. Metall. Mater. Trans. A 43, 4667 (2012).

    Article  CAS  Google Scholar 

  5. G.R. Zare, M. Divandari, and H. Arabi: Investigation on interface of Al/Cu couples in compound casting. J. Mater. Sci. Technol. 29, 190 (2013).

    Article  CAS  Google Scholar 

  6. E.M. Khoonsari, F. Jalilian, F. Paray, D. Emadi, and R.A.L. Drew: Interaction of 308 stainless steel insert with A319 aluminum casting alloy. J. Mater. Sci. Technol. 26, 833 (2010).

    Article  CAS  Google Scholar 

  7. J. Bruckner: Cold metal transfer has a future joining steel to aluminum. Weld. J. 84, 38 (2005).

    CAS  Google Scholar 

  8. S. Pontevichi, F. Bosselet, F. Barbeau, M. Peronnet, and J.C. Viala: Solid-liquid phase equilibria in the Al–Fe–Si system at 727 °C. J. Phase Equilib. Diffus. 25, 528 (2004).

    Article  CAS  Google Scholar 

  9. E. Aguado, A. Baquedano, U. Uribe, A.I. Fernández-Calvo, and A. Niklas: Comparative study of different interfaces of steel inserts in aluminum castings. Mater. Sci. Forum 765, 711 (2013).

    Article  Google Scholar 

  10. K.H. Choe, K.S. Park, B.H. Kang, G.S. Cho, K.Y. Kim, K.W. Lee, M.H. Kim, A. Ikenaga, and S. Koroyasu: Study of the interface between steel insert and aluminum casting in EPC. J. Mater. Sci. Technol. 24, 60 (2008).

    CAS  Google Scholar 

  11. B. Lemmens, B. Caklu, J. de Strycker, and K. Verbeken: The effect of Si on the intermetallics formation during hot dip aluminizing. J. Adv. Mater. Res. 922, 429 (2014).

    Article  CAS  Google Scholar 

  12. C.J. Wang and S.M. Chen: The high-temperature oxidation behavior of hot-dipping Al–Si coating on low carbon steel. Surf. Coat. Technol. 200, 6601 (2006).

    Article  CAS  Google Scholar 

  13. F.C. Yin, M.X. Zhao, Y.X. Liu, W. Han, and Z. Li: Effect of Si on growth kinetics of intermetallic compounds during reaction between solid iron and molten aluminum. Trans. Nonferrous Met. Soc. China 23, 556 (2013).

    Article  CAS  Google Scholar 

  14. T.S. Shih and S.H. Tu: Interaction of steel with pure Al, Al–7Si and A356 alloys. Mater. Sci. Eng., A 454–455, 349 (2007).

    Article  Google Scholar 

  15. W.J. Cheng and C.J. Wang: Microstructural evaluation of intermetallic layer in hot-dipped aluminide mild steel with silicon addition. Surf. Coat. Technol. 205, 4726 (2011).

    Article  CAS  Google Scholar 

  16. U.R. Kattner: Binary Alloy Phase Diagrams, 2nd ed. (ASM International, Materials Park, Ohio, 1990).

    Google Scholar 

  17. G. Ghosh: Aluminium–iron–silicon, Light Metal Systems: Phase Diagrams, Crystallographic and Thermodynamic Data. Landolt–Börnstein, New Series IV, Vol. 11A2 (Springer Verlag, Berlin, 2005).

    Google Scholar 

  18. G. Ghosh: Cost 507. Final Report Group B, The European Commission, 1998.

  19. G. Ghosh: Ternary Alloys, Vol. 5 (VCH publisher, Weinheim, Germany, 1992).

    Google Scholar 

  20. V.J. Raghavan: Al–Fe–Si aluminum–iron–silicon, section II: Phase diagram evaluations. J. Phase Equilib. Diffus. 23, 362 (2002).

    Article  CAS  Google Scholar 

  21. M.V. Akdeniz and A.O. Mekhrabov: The effect of substitutional impurities on evolution of Fe–Al diffusion layer. Acta Mater. 46, 1185 (1998).

    Article  CAS  Google Scholar 

  22. W. Fragner, B. Zberg, R. Sonnleitner, P.J. Uggowitzer, and J.F. Löffler: Interface reactions of Al and binary Al-alloys on mild steel substrates in controlled atmosphere. Mater. Sci. Forum 519–521, 1157 (2006).

    Article  Google Scholar 

  23. O. Dezellus, B. Digonnet, and M. Sacerdote-peronnet: Mechanical testing of steel/aluminum-silicon interface by push-out. Int. J. Adhes. Adhes. 27, 417 (2007).

    Article  CAS  Google Scholar 

  24. O. Dezellus, L. Milani, F. Bosselet, M. Sacerdote-Peronnet, and J.C. Viala: Mechanical testing of titanium/aluminum-silicon interface by push out. J. Mater. Sci. 43, 1749 (2008).

    Article  CAS  Google Scholar 

  25. G.H. Awan and F.U. Hasan: The morphology of coating/substrate interface in hot-dip-aluminized steel. Mater. Sci. Eng., A 472, 157 (2008).

    Article  Google Scholar 

  26. S. Madhavan, M. Kamaraj, and L. Vijayaraghavan: Microstructure and mechanical properties of cold metal transfer welded aluminum/dual phase steel. Sci. Technol. Weld. Joining 21, 194 (2016).

    Article  CAS  Google Scholar 

  27. J.A. Taylor: Iron containing intermetallic phases in Al–Si based casting. Procedia Mater. Sci. 1, 19 (2012).

    Article  CAS  Google Scholar 

  28. L. Backerud, G. Chai, and J. Tamminen: Solidification Characteristics of Aluminum Alloys. Vol. 2: Foundry Alloys (AFS/Scanaluminium, Stockholm, Sweden, 1990).

    Google Scholar 

  29. C. Wei-Jen and W. Chaur-Jeng: Observation of high-temperature phase transformation in the Si-modified aluminide coating on mild steel using EBSD. Mater. Charact. 61, 467 (2010).

    Article  Google Scholar 

  30. H. Springer, A. Kostka, E.J. Payton, D. Raabe, A. Kaysser-Pyzalla, and G. Eggeler: On the formation and growth of intermetallic phases during interdiffusion between low-carbon steel and aluminum alloys. Acta Mater. 59, 1586 (2011).

    Article  CAS  Google Scholar 

  31. H.R. Shahverdi, M.R. Ghomashchi, S.G. Shabestari, and J. Hejazi: Microstructure analysis of interfacial reaction between molten aluminum and solid iron. J. Mater. Process. Technol. 124, 345 (2002).

    Article  CAS  Google Scholar 

  32. W. Zhang, D. Sun, L. Han, W. Gao, and X. Qiu: Characterization of intermetallic compound in dissimilar material resistance spot welded joint of high strength steel and aluminum alloy. ISIJ Int. 51, 1870 (2011).

    Article  CAS  Google Scholar 

  33. L. Backerud, E. Krol, and J. Tamminen: Solidification Characteristics of Aluminum Alloys. Vol. 1: Wrought Alloys (Skanaluminium/Universitetsforlaget AS, Stockholm, Sweden, 1986).

    Google Scholar 

  34. L. Backerud: Kinetic aspects of the solidification of binary and ternary alloy systems. Jernkontorets Ann. 152, 109 (1968).

    CAS  Google Scholar 

  35. Q. Wang, X.S. Leng, T.H. Yang, and J.C. Yan: Effect of Fe–Al intermetallic compounds on interfacial bonding of clad material. Trans. Nonferrous Met. Soc. China 24, 279 (2014).

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Shahid Rajaee Teacher Training University (SRTTU), Tehran, 1678815811, Iran

    Maryam Salimi & Bahram Nami

  2. School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran, 1417614418, Iran

    Medhi Malekan

  3. Corrosion Research Group, Research Institute of Petroleum Industry (RIPI), Tehran, 1485733111, Iran

    Hamed Hoseiny

Authors
  1. Maryam Salimi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Medhi Malekan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Bahram Nami
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hamed Hoseiny
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Medhi Malekan.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Salimi, M., Malekan, M., Nami, B. et al. Microstructure characteristics and mechanical properties of the interface layer of coated steel insert-aluminum bimetals. Journal of Materials Research 32, 874–882 (2017). https://doi.org/10.1557/jmr.2017.32

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1557/jmr.2017.32

Search

Navigation