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Melting, Processing, and Properties of Disordered Fe-Al and Fe-Al-C Based Alloys

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Abstract

This article presents a part of the research work conducted in our laboratory to develop lightweight steels based on Fe-Al alloys containing 7 wt.% and 9 wt.% aluminum for construction of advanced lightweight ground transportation systems, such as automotive vehicles and heavy-haul truck, and for civil engineering construction, such as bridges, tunnels, and buildings. The melting and casting of sound, porosity-free ingots of Fe-Al-based alloys was accomplished by a newly developed cost-effective technique. The technique consists of using a special flux cover and proprietary charging schedule during air induction melting. These alloys were also produced using a vacuum induction melting (VIM) process for comparison purposes. The effect of aluminum (7 wt.% and 9 wt.%) on melting, processing, and properties of disordered solid solution Fe-Al alloys has been studied in detail. Fe-7 wt.% Al alloy could be produced using air induction melting with a flux cover with the properties comparable to the alloy produced through the VIM route. This material could be further processed through hot and cold working to produce sheets and thin foils. The cold-rolled and annealed sheet exhibited excellent room-temperature ductility. The role of carbon in Fe-7 wt.% Al alloys has also been examined. The results indicate that Fe-Al and Fe-Al-C alloys containing about 7 wt.% Al are potential lightweight steels.

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Acknowledgements

The authors are grateful to the Defence Research and Development Organization, Ministry of Defence, New Delhi, for the financial support in carrying out this research work as well as to Dr. Amol A. Gokhale, Director, DMRL, for his interest and encouragement. The authors would like to thank fellow officers and staff of various groups of DMRL such as ERG (melting and casting), MBG (tensile and creep), SFAG (metallography, SEM, and EPMA), CDG (radiography, forging, and rolling), ACG (chemical analysis), and GMS (sample making).

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Authors and Affiliations

  1. Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad, 500058, India

    V. V. Satya Prasad, Shivkumar Khaple & R. G. Baligidad

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  1. V. V. Satya Prasad
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  2. Shivkumar Khaple
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  3. R. G. Baligidad
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Correspondence to R. G. Baligidad.

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Satya Prasad, V.V., Khaple, S. & Baligidad, R.G. Melting, Processing, and Properties of Disordered Fe-Al and Fe-Al-C Based Alloys. JOM 66, 1785–1793 (2014). https://doi.org/10.1007/s11837-014-1065-1

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  • DOI: https://doi.org/10.1007/s11837-014-1065-1

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