Development and characterization of an iron aluminide coating on mild steel substrate obtained by friction surfacing and heat treatment

Troysi, Fernanda; Brito, Pedro

doi:10.1007/s00170-020-06310-w

Cited by 8 publications

(3 citation statements)

References 42 publications

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“…The FS approach can also be used to deposit multiple layer o top of each other, known as multi-layer friction surfacing (MLFS) or friction surfacing layer deposition (FSLD), leading to a solid-state layer deposition process. For coating applications, i.e., deposition of one single layer, FS was successfully performed for various material combinations like steels [12], aluminum alloys [13], copper [14], titanium alloys [15], Inconel [16], magnesium alloys [17], and, e.g., aluminum and steel [18] or low carbon steel over Inconel [19]. Further very challenging dissimilar material combinations are also achievable, as, e.g., Al/Ti joints enabled by hybrid approaches of friction stir welding (FSW) assisted by FS [20].…”

Section: Introductionmentioning

confidence: 99%

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Rath

Kallien

Roos

et al. 2023

Int J Adv Manuf Technol

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Friction surfacing (FS) is a solid-state layer deposition process for metallic materials at temperatures below their melting point. While the bonding of the deposited layers to the substrate is proven suitable for coating applications, so far the mechanical properties of additively manufactured stacks have not been systematically investigated. In particular, the effect of successive deposited FS layers, i.e., repetitive thermo-mechanical loading, on the interface properties as well as anisotropy and strength of the deposited stack is unknown. For this purpose, the mechanical properties of FS deposited multi-layer stacks from dissimilar aluminum alloys have been investigated, characterizing layer-to-layer as well as layer-to-substrate bonding interfaces via micro-flat tensile testing. Furthermore, directional dependencies in the stack and failure mechanisms are analyzed. The results show a homogeneous, fine-grained microstructure with average grain sizes between 4.2 and 4.6 μ m within the deposited material. The resulting tensile properties with no significant directional dependency present an ultimate tensile strength between 320 and 326 MPa exceeding the strength of the AA5083 H112 consumable base material. No difference was obtained in terms of layer-to-layer or layer-to-substrate interface strength. Furthermore, homogeneous hardness was observed within the deposited structure, which is in the range of AA5083 base material’s hardness of 91 HV. The results indicate that the FS process in conjunction with the material used is suitable for additively generated structures and highlight the potential of this solid-state layer deposition technology.

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Section: Introductionmentioning

confidence: 99%

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Rath

Kallien

Roos

et al. 2023

Int J Adv Manuf Technol

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“…Slightly differing from these results, the Fe 2 Al 5 phase of Al/Fe bimetals typically exhibits a microhardness value of approximately 1000 HV [7]. Troysi et al [29] have reported that the Fe 2 Al 5 phase of aluminized 1020 steel (with a Cr composition of approximately 0.03 wt.%) exhibits a hardness value of 1070 HV. However, in this study, the Fe 2 Al 5 (Cr) layer in Al-Si-Mg/STS420 bimetals exhibits a hardness of approximately 1260 HV, which is about 20% higher than that of the Fe 2 Al 5 layer in Al/Fe bimetals.…”

Section: Pointmentioning

confidence: 86%

Formation and Evolution of Interfacial Structure in Al–Si–Mg/Stainless Steel Bimetals during Hot-Dipping Process

Kim,

Lim,

Kayani

et al. 2024

Crystals

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Understanding trends in the formation of the intermetallic compound (IMC) layer in Al/Fe bimetallic composites can aid in significantly improving their mechanical properties. However, it is currently challenging to predict IMC layer formation during hot-dip aluminizing. Furthermore, the results from previous studies are difficult to compare owing to the variation in the process parameters used. Therefore, to understand how temperatures and holding times affect the thickness and hardness properties of IMC layers, we investigated the interfacial properties of aluminized stainless steel in molten Al-Si-Mg. AISI 420 stainless steel was hot-dip aluminized in an Al–Si–Mg alloy melt for 10–120 min at four different temperatures: 700, 750, 800, and 850 °C. Morphology, type, and element distribution of the phases formed in the reaction layer and the reduction rate of the aluminizing process were studied. Notably, while the reaction layer thickness increased with increasing aluminizing temperature when the holding time was low, long-term reaction caused the reaction layer to become thicker at lower temperatures. The mechanism of this morphological transformation is discussed. The results demonstrated effective trends in controlling the morphology of the intermetallic compound layer with respect to various hot-dip Al plating process parameters.

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“…Among these, iron aluminides with higher Al content such as Fe 3 Al (DO 3 ) and FeAl (B2) due to their low cost, are being possible substitute materials for high-temperature applications up to 1000 • C in aggressive environment [5][6][7][8][9]. However, iron aluminides have been poorly studied in the environment composed of (Na 2 SO 4 -V 2 O 5 ) molten salt.…”

Section: Introductionmentioning

confidence: 99%

High-Temperature Corrosion Performance of FeAl-Based Alloys Containing Carbon in Molten Salt

Kumar

Kant

Chand

et al. 2021

Metals

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Corrosion behavior of FeAl-based alloys containing carbon produced through arc melting in argon atmosphere has been studied at 500 °C to 700 °C. The samples were tested in the aggressive environment of molten salts (80%V2O5/20%Na2SO4). The corrosion behavior was observed by weight change method and the layer products formed were examined by using X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). The different phase components were observed in the surface layer after the test in Fe-22Al alloy. A protective Al2O3 layer was confirmed for Fe-22Al alloy containing carbon only. However, an additional TiO layer was also observed in Fe-22Al alloy containing carbon with Ti addition. The microstructural and XRD examinations revealed that this additional TiO layer protects better against penetration of corrosive media. The corrosion resistance behavior of FeAl-based alloys were addressed on the basis of microstructural evidence.

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Development and characterization of an iron aluminide coating on mild steel substrate obtained by friction surfacing and heat treatment

Cited by 8 publications

References 42 publications

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Formation and Evolution of Interfacial Structure in Al–Si–Mg/Stainless Steel Bimetals during Hot-Dipping Process

High-Temperature Corrosion Performance of FeAl-Based Alloys Containing Carbon in Molten Salt

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