Investigation of the Interface Reaction of Al and Binary Al-alloys on Mild Steel Substrates for Al Compound Casting
Research output: Thesis › Doctoral Thesis
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2012. 119 p.
Research output: Thesis › Doctoral Thesis
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TY - BOOK
T1 - Investigation of the Interface Reaction of Al and Binary Al-alloys on Mild Steel Substrates for Al Compound Casting
AU - Fragner, Werner
N1 - no embargo
PY - 2012
Y1 - 2012
N2 - The requirements of politics and manufacturers for weight-saving and low-cost production of prospective of components for future transport vehicles are getting more and more severe. For this reason the concept of multi-material mix is of increasing importance. In this context aluminum-iron compounds produced by means of compound casting (steel insert recast with aluminum) are considered to be of particular importance due to their high potential for cost savings and integration of function. An essential and critical aspect of such compound castings is the formation of intermetallic phases (IMP) at the Al-Fe interface. Both the nature and the kinetics of potential IMPs are not well understood and require a systematic investigation. This work deals with the formation of intermetallic phases at the interface of steel to aluminum and aluminum alloys. Aim of this thesis is to determine the emerging phases, characterize the kinetics and model the time dependent phase formation if possible. For this reason several experimental methods of phase formation were applied after producing calibration samples of defined phases in the laboratory: •Gravity casting with different Al-Fe mass ratios •Wetting experiments under a controlled atmosphere •Dipping trials in pure aluminum and binary commercial alloys •Squeeze Casting of inserts in an industrial environment. The system Al-Si, which is dominant in shape casting industry, produces the most complex phase morphologies with different, simultaneously emerging phases at the interface such as Fe2(Al,Si)5 (η), FeAl4Si (τ6), Fe2Al2Si (τ1) and Fe3Al4Si2 (τ3). This leads to a reduced interface thickness among other things, which has a negative influence on the bonding in the industrial environment. However, it could be also shown that a chemical bonding can add strength to the compound additionally to shape- and force bonding, which range from at least 5 MPa (Al-7Si) to a maximum of 24 MPa (Al 7Zn). Concluding this thesis are practical tips and parameters for the caster on how to obtain chemical bonding in the industrial environment.
AB - The requirements of politics and manufacturers for weight-saving and low-cost production of prospective of components for future transport vehicles are getting more and more severe. For this reason the concept of multi-material mix is of increasing importance. In this context aluminum-iron compounds produced by means of compound casting (steel insert recast with aluminum) are considered to be of particular importance due to their high potential for cost savings and integration of function. An essential and critical aspect of such compound castings is the formation of intermetallic phases (IMP) at the Al-Fe interface. Both the nature and the kinetics of potential IMPs are not well understood and require a systematic investigation. This work deals with the formation of intermetallic phases at the interface of steel to aluminum and aluminum alloys. Aim of this thesis is to determine the emerging phases, characterize the kinetics and model the time dependent phase formation if possible. For this reason several experimental methods of phase formation were applied after producing calibration samples of defined phases in the laboratory: •Gravity casting with different Al-Fe mass ratios •Wetting experiments under a controlled atmosphere •Dipping trials in pure aluminum and binary commercial alloys •Squeeze Casting of inserts in an industrial environment. The system Al-Si, which is dominant in shape casting industry, produces the most complex phase morphologies with different, simultaneously emerging phases at the interface such as Fe2(Al,Si)5 (η), FeAl4Si (τ6), Fe2Al2Si (τ1) and Fe3Al4Si2 (τ3). This leads to a reduced interface thickness among other things, which has a negative influence on the bonding in the industrial environment. However, it could be also shown that a chemical bonding can add strength to the compound additionally to shape- and force bonding, which range from at least 5 MPa (Al-7Si) to a maximum of 24 MPa (Al 7Zn). Concluding this thesis are practical tips and parameters for the caster on how to obtain chemical bonding in the industrial environment.
KW - Aluminum
KW - Aluminium
KW - Steel
KW - Iron
KW - Hybrid Casting
KW - Compound Casting
KW - Al13Fe3
KW - Al3Fe
KW - Al5Fe2
KW - Intermetallics
KW - Interface
KW - Layer Thickness
KW - Dipping Trials
KW - SEM
KW - REM
KW - Chemical Bonding
KW - Al-Fe
KW - Fe-Al
KW - Interface Modeling
KW - Al-Si-Fe
KW - Al-Cu-Fe
KW - Al-Mg-Fe
KW - Al-Zn-Fe
KW - Magsimal59
KW - AlSi7Mg
KW - AlSi7
KW - AlSi12
KW - AlSi17
KW - Stahl
KW - Eisen
KW - Hybridguss
KW - Verbundguss
KW - Leichtbau
KW - Hybridbauweise
KW - Stahl-Alu
KW - Alu-Stahl
KW - Intermetallische Verbindungen
KW - Verbindungszone
KW - Chemischer Verbund
KW - Stoffschluss
KW - Tauchversuche
KW - Interfacemodellierung
KW - Wetting Experiment
KW - Benetzungsversuche
KW - Benetzungswinkel
KW - Wetting Angle
KW - Mechanical Properties
KW - Interface Kinetics
KW - Interfacebildung
KW - Interface Formation
KW - Practical Advice
KW - Casting
KW - Aluminum
KW - Aluminium
KW - Steel
KW - Iron
KW - Hybrid Casting
KW - Compound Casting
KW - Al13Fe3
KW - Al3Fe
KW - Al5Fe2
KW - Intermetallics
KW - Interface
KW - Layer Thickness
KW - Dipping Trials
KW - SEM
KW - REM
KW - Chemical Bonding
KW - Al-Fe
KW - Fe-Al
KW - Interface Modeling
KW - Al-Si-Fe
KW - Al-Cu-Fe
KW - Al-Mg-Fe
KW - Al-Zn-Fe
KW - Magsimal59
KW - AlSi7Mg
KW - AlSi7
KW - AlSi12
KW - AlSi17
KW - Stahl
KW - Eisen
KW - Hybridguss
KW - Verbundguss
KW - Leichtbau
KW - Hybridbauweise
KW - Stahl-Alu
KW - Alu-Stahl
KW - Intermetallische Verbindungen
KW - Verbindungszone
KW - Chemischer Verbund
KW - Stoffschluss
KW - Tauchversuche
KW - Interfacemodellierung
KW - Wetting Experiment
KW - Benetzungsversuche
KW - Benetzungswinkel
KW - Wetting Angle
KW - Mechanical Properties
KW - Interface Kinetics
KW - Interfacebildung
KW - Interface Formation
KW - Practical Advice
KW - Casting
M3 - Doctoral Thesis
ER -
