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<p>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&#xa0;A and a low traverse speed of 13&#xa0;mm/s result in a maximum IMT of 7.7&#xa0;μm due to a significant heat input of 48&#xa0;J/mm, promoting extensive iron (Fe) and aluminium (Al) diffusion. The Fe-Al interface predominantly consisted of binary IMC phases such as FeAl-B2, FeAl<sub>2</sub>, and Fe<sub>2</sub>Al<sub>5</sub>, as well as ternary IMC phases like Al<sub>2</sub>Fe<sub>3</sub>Si<sub>4</sub>, Al<sub>2</sub>(Fe, Si)<sub>3</sub>, and FeSi<sub>2</sub>Al<sub>3</sub>. FeAl grows towards the Fe side, and Fe<sub>2</sub>Al<sub>5</sub> dendrites grow towards the Al side. Si in the inter-dendritic liquid Al triggered the sequence L→L + Fe<sub>2</sub>Al<sub>5</sub>→ L + Fe<sub>2</sub>Al<sub>5</sub> + FeAl + Si → Fe<sub>2</sub>Al<sub>5</sub> + FeAl + FeSi<sub>2</sub>Al<sub>3</sub>. Higher elastic modulus (E) and phase hardness (H) values of the bimetallic interface were obtained with the condition where the FeAl: Fe<sub>2</sub>Al<sub>5</sub> ratio of 1:3 and an IMT of less than 4&#xa0;μm are fulfilled, and it generally occurred at the lower heat input (≤ 43&#xa0;J/mm). The results indicated that the interface developed at 43&#xa0;J/mm has superior strength, reaching up to 73&#xa0;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.</p> Graphical Abstract <p></p>

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

  • 期刊论文

  • 发表日期：

    2025年3月1日

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

摘要

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