On the Characteristic Evaluation of Bimetallic Interface of Carbon Steel (EN31) and Aluminium (AA4043) for Wire Arc Additive Manufacturing

IF 4 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Metals and Materials International Pub Date : 2025-03-01 DOI:10.1007/s12540-025-01919-6

Afsal Ahammed CP, Somnath Nandi, Amrit Raj Paul, B. Sreejith, Jose MJ, Manidipto Mukherjee

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Abstract

This study investigated the formation of intermetallic compounds (IMCs) at the carbon steel (EN31)-aluminium (AA4043) interface, focusing on the influence of variable heat input on the intermetallic thickness (IMT), element diffusion, phase transformation, texture orientation and mechanical behavior. The research showed that a high current of 36 A and a low traverse speed of 13 mm/s result in a maximum IMT of 7.7 μm due to a significant heat input of 48 J/mm, promoting extensive iron (Fe) and aluminium (Al) diffusion. The Fe-Al interface predominantly consisted of binary IMC phases such as FeAl-B2, FeAl₂, and Fe₂Al₅, as well as ternary IMC phases like Al₂Fe₃Si₄, Al₂(Fe, Si)₃, and FeSi₂Al₃. FeAl grows towards the Fe side, and Fe₂Al₅ dendrites grow towards the Al side. Si in the inter-dendritic liquid Al triggered the sequence L→L + Fe₂Al₅→ L + Fe₂Al₅ + FeAl + Si → Fe₂Al₅ + FeAl + FeSi₂Al₃. Higher elastic modulus (E) and phase hardness (H) values of the bimetallic interface were obtained with the condition where the FeAl: Fe₂Al₅ ratio of 1:3 and an IMT of less than 4 μm are fulfilled, and it generally occurred at the lower heat input (≤ 43 J/mm). The results indicated that the interface developed at 43 J/mm has superior strength, reaching up to 73 MPa, 54% higher than the high heat input sample. However, the poor elongation suggested extreme brittleness due to continuous IMCs. Further research is needed to optimize interface characteristics by controlling the cooling rate, especially for cyclic and severe tensile loads applications.

Graphical Abstract

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电弧增材制造用碳钢（EN31）与铝（AA4043）双金属界面特性评价

本文研究了碳钢(EN31)-铝（AA4043）界面金属间化合物（IMCs）的形成，重点研究了不同热输入对金属间化合物厚度（IMT）、元素扩散、相变、织构取向和力学行为的影响。研究表明，在36 a的大电流和13 mm/s的低导线速度下，由于48 J/mm的大量热输入，促进了铁（Fe）和铝（Al）的广泛扩散，最大IMT为7.7 μm。Fe- al界面主要由二元IMC相组成，如FeAl-B2、FeAl2和Fe2Al5，以及三元IMC相，如Al2Fe3Si4、Al2(Fe, Si)3和FeSi2Al3。FeAl向Fe侧生长，Fe2Al5枝晶向Al侧生长。枝晶间液体Al中的Si触发了L→L + Fe2Al5→L + Fe2Al5 + FeAl + Si→Fe2Al5 + FeAl + FeSi2Al3。在FeAl: Fe2Al5比为1:3、IMT小于4 μm的条件下，双金属界面的弹性模量(E)和相硬度(H)值较高，且通常发生在较低的热输入（≤43 J/mm）下。结果表明，在43 J/mm下发展的界面具有较好的强度，达到73 MPa，比高热输入样品高54%。然而，较低的延伸率表明，由于持续的imc，脆性极高。需要进一步研究通过控制冷却速度来优化界面特性，特别是在循环和剧烈拉伸载荷应用中。图形抽象

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来源期刊

Metals and Materials International 工程技术-材料科学：综合

CiteScore

7.10

自引率

8.60%

发文量

197

审稿时长

3.7 months

期刊介绍： Metals and Materials International publishes original papers and occasional critical reviews on all aspects of research and technology in materials engineering: physical metallurgy, materials science, and processing of metals and other materials. Emphasis is placed on those aspects of the science of materials that are concerned with the relationships among the processing, structure and properties (mechanical, chemical, electrical, electrochemical, magnetic and optical) of materials. Aspects of processing include the melting, casting, and fabrication with the thermodynamics, kinetics and modeling.