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<p>Fe/Cu bimetallic composites are increasingly applied in industries like automotive and aerospace, yet the influence of trace zinc (Zn) in their liquid–solid compound casting remains underexplored. This study systematically investigates the effects of Zn addition on the microstructural evolution and mechanical properties of the near-interface copper layer in Fe/Cu bimetallic. Experimental results identified 1.3 wt.% as the optimal Zn content. Zn incorporation significantly optimized tin bronze solidification, narrowing its crystallization temperature range by approximately 35&#xa0;°C and reducing crystallization enthalpy by about 37.85%, thus accelerating the phase transition rate. This remarkably improved Sn element segregation (reducing the dendrite-to-interdendrite Sn difference from ~ 7.78 to ~ 2.32%) and refined the copper layer's grain size, with the maximum grain area decreasing from 15,320.3 to 8500.5 μm<sup>2</sup>. Zn addition significantly enhanced the overall mechanical performance of Fe/Cu bimetallic composites, increasing copper layer hardness by 19% to 121.5 HBW (at 1.3 wt.% Zn content). Furthermore, at 2 wt.% Zn content, the shear strength increased to 264.48&#xa0;MPa, a rise of approximately 12.8%, profoundly strengthening the metallurgical bond. These findings offer valuable mechanistic insights and practical guidance for optimizing the mechanical performance and interfacial strength of Fe/Cu bimetallic composites.</p>

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Effect of Elemental Zn on Interfacial and Near-Interfacial Copper Layers of Fe/Cu Bimetallic Composites

  • 期刊论文

  • 发表日期：

    2026年2月8日

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  • Guowei Zhang,
  • Zhaojie Wang,
  • Hong Xu,
  • Xiaoyan Ren

摘要

Fe/Cu bimetallic composites are increasingly applied in industries like automotive and aerospace, yet the influence of trace zinc (Zn) in their liquid–solid compound casting remains underexplored. This study systematically investigates the effects of Zn addition on the microstructural evolution and mechanical properties of the near-interface copper layer in Fe/Cu bimetallic. Experimental results identified 1.3 wt.% as the optimal Zn content. Zn incorporation significantly optimized tin bronze solidification, narrowing its crystallization temperature range by approximately 35 °C and reducing crystallization enthalpy by about 37.85%, thus accelerating the phase transition rate. This remarkably improved Sn element segregation (reducing the dendrite-to-interdendrite Sn difference from ~ 7.78 to ~ 2.32%) and refined the copper layer's grain size, with the maximum grain area decreasing from 15,320.3 to 8500.5 μm2. Zn addition significantly enhanced the overall mechanical performance of Fe/Cu bimetallic composites, increasing copper layer hardness by 19% to 121.5 HBW (at 1.3 wt.% Zn content). Furthermore, at 2 wt.% Zn content, the shear strength increased to 264.48 MPa, a rise of approximately 12.8%, profoundly strengthening the metallurgical bond. These findings offer valuable mechanistic insights and practical guidance for optimizing the mechanical performance and interfacial strength of Fe/Cu bimetallic composites.