Effect of alumina on Fe-Al intermetallics at the SS-Al bimetallic interface fabricated via wire arc directed energy deposition

IF 11.2 1区 材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY
Amrit Raj Paul, Jayshri Dumbre, Manidipto Mukherjee, Dilpreet Singh, Edwin LH. Mayes, Matthew R. Field, Maciej Mazur, Dong Qiu
{"title":"Effect of alumina on Fe-Al intermetallics at the SS-Al bimetallic interface fabricated via wire arc directed energy deposition","authors":"Amrit Raj Paul, Jayshri Dumbre, Manidipto Mukherjee, Dilpreet Singh, Edwin LH. Mayes, Matthew R. Field, Maciej Mazur, Dong Qiu","doi":"10.1016/j.jmst.2025.06.013","DOIUrl":null,"url":null,"abstract":"The development of a high-quality stainless steel (SS)-aluminium (Al) bimetallic transitionally graded structure (TGS) via metal additive manufacturing process has been challenging due to the formation of brittle and crack-prone Iron (Fe)- Al intermetallic compounds (IMCs) at the bimetallic interface. However, it has been observed that the addition of ternary alloying elements can significantly improve the metallurgical and mechanical properties of these IMCs. This study investigates the intricate influence of alumina particles on the SS-Al interface, uncovering insights into melt pool forces, tri-layered IMC formation, nano-grained IMC layers, and an inverse Hall-Petch relationship. Three thin-walled SS-Al structures were deposited via wire arc directed energy deposition (WA-DED), incorporating varying alumina content levels (20, 30, and 40 mg/mm). Alumina decomposition released elemental and gaseous oxygen, affecting IMC layer thickness. Oxygen content at the interface increased with alumina concentration (from 20 mg/mm to 40 mg/mm), which in turn altered Marangoni and buoyancy forces, significantly impacting the IMC thickness and respective grain size. Energy dispersive X-ray spectroscopy and electron back-scattered diffraction analyses revealed FeAl, Fe<sub>2</sub>Al<sub>5</sub>, and FeAl<sub>3</sub> layers, with Fe<sub>2</sub>Al<sub>5</sub> layer thickness increasing with alumina content. The nanometric grain size of Fe<sub>2</sub>Al<sub>5</sub> and FeAl<sub>3</sub> (∼77.69 nm and 52.68 nm) were observed at the bimetallic interface of lower alumina content (20 mg/mm) which justifies their respective hardness with the inverse Hall-Petch relationship. These findings provide valuable insights into interface dynamics and offer quantitative data for optimising SS-Al structures in diverse applications.","PeriodicalId":16154,"journal":{"name":"Journal of Materials Science & Technology","volume":"19 1","pages":""},"PeriodicalIF":11.2000,"publicationDate":"2025-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Materials Science & Technology","FirstCategoryId":"88","ListUrlMain":"https://doi.org/10.1016/j.jmst.2025.06.013","RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0

Abstract

The development of a high-quality stainless steel (SS)-aluminium (Al) bimetallic transitionally graded structure (TGS) via metal additive manufacturing process has been challenging due to the formation of brittle and crack-prone Iron (Fe)- Al intermetallic compounds (IMCs) at the bimetallic interface. However, it has been observed that the addition of ternary alloying elements can significantly improve the metallurgical and mechanical properties of these IMCs. This study investigates the intricate influence of alumina particles on the SS-Al interface, uncovering insights into melt pool forces, tri-layered IMC formation, nano-grained IMC layers, and an inverse Hall-Petch relationship. Three thin-walled SS-Al structures were deposited via wire arc directed energy deposition (WA-DED), incorporating varying alumina content levels (20, 30, and 40 mg/mm). Alumina decomposition released elemental and gaseous oxygen, affecting IMC layer thickness. Oxygen content at the interface increased with alumina concentration (from 20 mg/mm to 40 mg/mm), which in turn altered Marangoni and buoyancy forces, significantly impacting the IMC thickness and respective grain size. Energy dispersive X-ray spectroscopy and electron back-scattered diffraction analyses revealed FeAl, Fe2Al5, and FeAl3 layers, with Fe2Al5 layer thickness increasing with alumina content. The nanometric grain size of Fe2Al5 and FeAl3 (∼77.69 nm and 52.68 nm) were observed at the bimetallic interface of lower alumina content (20 mg/mm) which justifies their respective hardness with the inverse Hall-Petch relationship. These findings provide valuable insights into interface dynamics and offer quantitative data for optimising SS-Al structures in diverse applications.

Abstract Image

氧化铝对丝弧定向能沉积制备的SS-Al双金属界面上Fe-Al金属间化合物的影响
由于在双金属界面处形成脆性和易开裂的铁(Fe)-铝金属间化合物(IMCs),通过金属增材制造工艺开发高质量的不锈钢(SS)-铝(Al)双金属过渡梯度结构(TGS)一直具有挑战性。然而,三元合金元素的加入可以显著改善这些IMCs的冶金性能和力学性能。本研究探讨了氧化铝颗粒对SS-Al界面的复杂影响,揭示了熔池力,三层IMC形成,纳米颗粒IMC层以及逆Hall-Petch关系的见解。通过电弧定向能沉积(WA-DED)沉积了三个薄壁SS-Al结构,包含不同的氧化铝含量水平(20、30和40 mg/mm)。氧化铝分解释放单质氧和气态氧,影响IMC层厚度。界面氧含量随着氧化铝浓度的增加而增加(从20 mg/mm增加到40 mg/mm),从而改变了Marangoni力和浮力,显著影响了IMC厚度和各自的晶粒尺寸。能量色散x射线能谱和电子背散射衍射分析显示FeAl、Fe2Al5和FeAl3层,Fe2Al5层厚度随氧化铝含量的增加而增加。在较低氧化铝含量(20 mg/mm)的双金属界面上观察到Fe2Al5和FeAl3的纳米晶粒尺寸(~ 77.69 nm和52.68 nm),这证明了它们各自的硬度具有相反的Hall-Petch关系。这些发现为界面动力学提供了有价值的见解,并为优化不同应用中的SS-Al结构提供了定量数据。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 求助全文
来源期刊
Journal of Materials Science & Technology
Journal of Materials Science & Technology 工程技术-材料科学:综合
CiteScore
20.00
自引率
11.00%
发文量
995
审稿时长
13 days
期刊介绍: Journal of Materials Science & Technology strives to promote global collaboration in the field of materials science and technology. It primarily publishes original research papers, invited review articles, letters, research notes, and summaries of scientific achievements. The journal covers a wide range of materials science and technology topics, including metallic materials, inorganic nonmetallic materials, and composite materials.
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
确定
请完成安全验证×
copy
已复制链接
快去分享给好友吧!
我知道了
右上角分享
点击右上角分享
0
联系我们:info@booksci.cn Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。 Copyright © 2023 布克学术 All rights reserved.
京ICP备2023020795号-1
ghs 京公网安备 11010802042870号
Book学术文献互助
Book学术文献互助群
群 号:604180095
Book学术官方微信