Surface behaviour of as-Cast Al–Fe intermetallic composites

Abstract

In order to produce energy-efficient material for tribological applications, Al-Fe inter-metallic composites have been produced by liquid metallurgy route. Iron content of the composites varies from 1.67 to 11.2 wt.%. These composites have been tested for their wear properties at different parameters. Debris and wear tracks have been studied in detail to see the surface effects during dry sliding and have been correlated to wear properties. Observations show that low loads and sliding velocities are dominated by oxidative debris and largely covered wear track surface with smooth oxide layer is observed. Whereas metallic debris dominates at higher loads and sliding velocities and highly deformed wear track surface with deep grooves and gross delamination were observed. Further, wear rate is seen to increase continuously with load whereas with sliding velocity it attains a minima after initial decrease and then increases continuously. Low solubility of iron supports the formation of FeAl 3 and an increase in hardness from 95 to 179 VHN continuously improves the wear resistance with increase in percentage iron.

Densification Behaviour in the Fabrication of Al-Fe Metal Matrix Composite Using Powder Metallurgy Route

“…A brief study of earlier investigations related to Al-Fe binary system describes detailed ideas regarding the formation of intermetallic compounds, produced by a variety of techniques like mechanical alloying and solid-and liquidphase sintering. For example, Kang and Hu [16] reported the swelling behaviour of reactive sintering of Fe-29 at.% Al mixtures due to the formation of an intermediate phase having chemical formula Fe 2 Al 5 at the temperature range of 500 • C-750 • C. One of the authors of the present investigation has already reported the formation of Al 3 Fe intermetallics in the Al-Fe composites which has been prepared by dispersion of iron in aluminium melt by impeller mixing and bottom pouring chill casting technique [2]. The iron content for the above investigation varies from 1.67 to 11.2 wt%.…”

“…Therefore in P/M process, to achieve optimum density of a particulate composite of two-component system, it is necessary to construct preliminarily investigations on the densification behaviour with the help of experimental results. In a comprehensive study, it is found that most of the earlier investigations, related to Al-Fe binary phase system, are focused either on liquid-phase sintering and/or iron-rich composition (more than 20 wt.% Fe) [2,16]. Therefore in the present investigation, an attempt has been made to examine the compaction and sintering behaviour of Al-rich Al-Fe binary phase system.…”

“…Aluminium matrix composites (AMCs) are one of the most demanding engineering materials in the category of metal matrix composites (MMCs) due to combination of their light weight and excellent mechanical and tribological properties. These composites have been widely used for structural, nonstructural, and functional applications in automotive and aerospace industries [1][2][3]. Powder metallurgy (P/M) route is one of the most widely used methods for producing AMCs due to its low processing costs as well as the ease and the accuracy to obtain near net shaped components of complex geometry.…”

Investigation of Graphite Influence on Al/Fe and Al2024/Fe Metal Matrix Composites

“…In most of earlier investigations, related Al-Fe binary system, are focused either liquid-phase sintering or iron-rich composition (more than 20% wt. Fe) [5,6]. The hike of density due to Fe addition was compensated by addition of graphite (Gr).…”

Corrosion of Mechanically Alloyed Nanostructured FeAl Intermetallic Powders

“…In the past, intermetallic materials based on aluminum with transition metals such as Ni, Ti, Co, and Fe have been extensively investigated [1][2][3][4][5][6][7][8][9]. Particularly, the Fe 40 Al 60 system has been very attractive due to several characteristics such as low cost, good mechanical performance at elevated temperatures, low density, and excellent oxidation-corrosion resistance.…”