An innovative joint interface design for reducing intermetallic compounds and improving joint strength of thick plate friction stir welded Al/Mg joints

Friction stir welding of dissimilar Al/Mg thick plates still faces severe challenges, such as poor formability, formation of thick intermetallic compounds, and low joint strength. In this work, two joint configurations, namely inclined butt(conventional butt) and serrated interlocking(innovative butt), are proposed for improving weld formation and joint quality. The results show that a continuous and straight intermetallic compound layer appears at the Mg side interface in conventional butt joint, and the maximum average thickness reaches about 60.1 μm.Additionally, the Mg side interface also partially melts, forming a eutectic structure composed of Mg solid solution and Al_(12)Mg_(17) phase.For the innovative butt joint, the Mg side interface presents the curved interlocking feature, and intermetallic compounds can be reduced to less than 10 μm. The joint strength of innovative butt joint is more than three times that of conventional butt joint. This is due to the interlocking effect and thin intermetallic compounds in the innovative joint.

Fe-Al金属间化合物的第一性原理研究综述

Fe-Al金属间化合物具有密度低、比强度高、抗高温氧化和耐腐蚀性良好等优点,且成本低廉,成为镍基高温合金潜在的替代结构材料。综述了利用第一性原理计算研究元素掺杂/微合金化对Fe-Al金属间化合物及涂层的室温脆性、高温强度、界面结合、抗高温氧化及耐腐蚀性能影响的研究进展,设计了第一性原理研究B2型Fe-Al合金耐氯化盐腐蚀机理的理论计算方案,展望了第一性原理计算应用于Fe-Al合金及涂层材料研究的发展方向。

EFFECTS OF HIGH-ENERGY BALL MILLING ON STRUCTURE AND MECHANICAL PROPERTIES OF L1_2 INTERMETALLIC COMPOUND Al_(67)Mn_8Ti_(25)

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Microstructure of the Ductile Phase in Intermetallic Compound Ni_(50)Al_(20)Fe_(30)

The microstructure of the single hot extruded and annealed Ni50Al20Fe30Y0.003 intermetallic compound alloys has been examined by means of high resolution electron microscopy (HREM). In these extruded and annealed alloys. the ductile phase is of a mixture of the disordered fcc γ matrix and or dered γ' precipitates. This fact well interprets the reason why the degree of annealing treatment can influence the strength and ductility of these alloys. The HREM observation revealed directly that there was some strain concentration at γ'-γ interfaces, due to the presence of more iron atoms in these two phases. The fixed orientation relationship between the γ phase and γ' precipitates was identified to be {001}γ||{00 }γ' and <100 >γ|| < 100 > γ'

Electronic Structure Effect on Model Cluster for L1_2 Structure of Al_3Ti Intermetallic Compound with an Addition of Alloying Elements Fe, Ni and Cu

By use of self-consistent field Xα scattered-wave (SCF-Xα-SW) method, the electronic structure was calculated for four models of Ti4Al14X (X=Al, Fe, Ni and Cu) clusters. The Ti4Al14X cluster was developed based on L12 Al3Ti-base intermetallic compound. The results are presented using the density of states (DOS) and one-electron properties, such as relative binding tendency between the atom and the model cluster, and hybrid bonding tendency between the alloying element and the host atoms. By comparing the four models of Ti4Al14X cluster, the effect of the Fe, Ni or Cu atom on the physical properties of Al3Ti-based L12 intermetallic compounds is analyzed. The results indicate that the addition of the Fe, Ni or Cu atom intensifies the relative binding tendency between Ti atom and Ti4Al14X cluster. It was found that the Fermi level (EF) lies in a maximum in the DOS for Ti4Al14Al cluster; on the contrary, the EF comes near a minimum tn the DOS for Ti4Al14X (X=Fe, Ni and Cu) cluster. Thus the L12 crystal structure for binary Al3Ti alloy is unstable, and the addition of the Fe, Ni or Cu atom to Al3Ti is benefical to stabilize L12 crystal structure. The calculation also shows that the Fe, Ni or Cu atom strengthens the hybrid bonding tendency between the central atom and the host atoms for Ti4Al14X cluster and thereby may lead to the constriction of the lattice of Al3Ti-base intermetallic compounds.

Effect of intermetallic compound thickness on anisotropy of Al/Cu honeycomb rods fabricated by hydrostatic extrusion process

The effect of intermetallic compound （IMC） thickness on the thermal and mechanical properties of Al/Cu honeycomb rods was investigated. The Al/Cu honeycomb rods were fabricated using repeated hydrostatic extrusions at 200 ℃. During the process, an IMC layer with 1μm in thickness was generated at the Al/Cu interface. Different IMC thicknesses were obtained by post-heat treatment at 420 ℃ for 0.5 to 2 h. The IMC thickness increased to 10.1μm. The IMC layers were identified as Al2Cu （θ）, AlCu （η2）, and Al4Cu9（γ1） phases. The thermal conductivities in the longitudinal direction and cross direction decreased by 11.9% （（268±4.8） to （236±4.4） W/（m·K）） and 10.4% （（210±3.2） to （188±2.8） W/（m＆#183;K））, respectively, with increasing IMC thickness. The ultimate tensile strength and elongation of the Al/Cu honeycomb rod are （103±8.4） MPa and （73±6.2）%, respectively. The ultimate tensile strength increased to （131±6.5） MPa until the IMC thickness reached 7.7μm. It subsequently decreased to （124±3.9） MPa until the IMC thickness reached 10.1μm. The elongation of the Al/Cu honeycomb rod then sharply decreased to （29±2.5）% with increasing IMC thickness.

Study on microstructure and properties of high velocity arc sprayed Fe_3Al intermetallic coating

Coating structural materials with Fe 3Al based intermetallics may rapidly lead to industrial application of their environment and wear resistant features. In the present study, high velocity arc spraying (HVAS) was used to in situ synthesize Fe 3Al intermetallic coating. The microstructural characterization and properties of the coating have been investigated. The microstructure was found to consist of Fe 3Al based intermetallic (D0 3 and B2) and α Fe regions together with fine oxide (α Al 2O 3) layers. TEM images of coating show that the solidified lamellae are polycrystalline and have a grain size of the order of about 150 nm , and there also exists amorphous state in some areas. It can be concluded that a very high cooling rate has been obtained during HVAS process. Moreover, the coating has relatively higher adhesion strength and microhardness, as well as lower density and porosity.

Formation of Intermetallic Compound in Iron-Aluminum Alloys

The mechanism of iron and aluminum intermetallics formation in the reactive sintering of iron and aluminum mixing powders has been studied by investigating iron aluminum diffusion couples.The couples were treated at 600℃,700℃,800℃,900℃ and 1000℃ respectively.It was found that an Al rich intermetallics FeAl 3 has formed in iron adjacent to the interface of iron and aluminum by aluminum diffusion into iron at 600℃ (below the eutectic temperature),and that in the case above 700℃ (above the eutectic temperature) there was a liquid,an intermetallics Fe 2Al 5 has formed in both side of the interface.The diffusion of iron and aluminum atoms is companied with the Fe Al reaction during the treatment under the both conditions.The diffusion coefficients of iron and aluminum and the activation energy were determined.The mechanism of the intermetallics formation in the couples is also discussed.

ONE-CELL-STATE METHOD FOR DETERMINATION OF ELECTRONIC STRUCTURE OF INTERMETALLIC COMPOUNDS

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Microstructure and corrosion resistance of Fe-Al intermetallic coating on 45 steel synthesized by double glow plasma surface alloying technology

A binary Fe-Al alloyed layer was synthesized on 45 steel by means of double glow plasma surface alloying technique. The corrosion-resisting layer prepared is composed of a sedimentary layer and a diffusion layer, with a total thickness of about 180 μm. The aluminum content of the alloyed layer shows gradual change from surface to the inside of substrate. The ideal profile is beneficial to the metallurgical bonding of the surface alloying layer with substrate materials. The microstructure of both layers consists of the Fe-Al intermetallic compound, which is FeAl with B2 structure in the sedimentary layer and Fe3Al with incompletely ordered DO3 structure in the diffusion layer. The protective film exhibits high micro-hardness. In comparison with the substrate of 45 steel, the corrosion resistance of the aluminized sample is much higher in 2.0% Na2S and 0.05 mol/L Na2SO4 + 0.5 mol/L NaCl mixed solutions.

Structure of the Intermetallic Compound Ni_3Al Synthesized under Compression of the Powder Mixture of Pure Elements Part Ⅰ: Phase Composition and Microstructure of Main Phase

It was shown by TEM and X-ray analysis that there are four types of grains of the main Ni3Al phase in the structure of the intermetallic obtained by the self-propagation high temperature method (SHS). Every type of grains has its own domain and dislocation structure. There are mono- and polydomains with and without dislocations. The grains of the main phase of monoand polydomains without dislocations and polydomains with dislocations were formed by diffusion in the solid phase. In these conditions NiAl3 phase is located on the grain boundary of the main phase. The Ni2Al3 phase is located at the triple joints of the main phase.

Structure of the Intermetallic Compound Ni_3Al Synthesized under Compression of the Powder Mixture of Pure Elements Part Ⅱ: Influence of Alloying by Boron on the Phase Composition and the Microstructure of Grains of the Main Phase

The Ni_3B phase was formed when boron (0.5 at. pct B) was added to the intermetallic of sto- ichiometric and off-stoichiometric (Ni-24 at. pct Al) compounds. In the alloy of stoichiometric composition the particles of Ni_3B phase has the size around 0.1μm and is located on the grain boundary of the main phase. The decreasing of concentrations of Al in the ofF-stoichiometric alloy leads to increase in the degree of the long-range order parameter, increasing the concen- trations of boron in the solid solution and decreasing its localization on the grain boundary. Microalloying of boron leads to increasing in the fraction of grain monodomains with disloca- tions up to 0.7 in the alloy of the off-stoichiometric composition and up to 1 in the alloy of the stoichiometric composition. It was established the correlation between the degree of the concentration inhomogeneity, average density of the dislocations and the average long range-order parameter.

Microstructural characteristics of intermetallic phases in spray-deposition Al-8.5Fe-1.3V-1.7Si alloy

Analysis electron microtechnique (AEM) and high resolution electron microtechnique (HREM) studies were conducted on a spray deposition Al 8.5Fe 1.3V 1.7Si(mass fraction, %) alloy to determine the characteristics of the intermetallic phases. The results show that the striking characteristics of the microstructures in as deposited and as extruded alloys indicate the presence of a large amounts of homogeneously distributed fine particles and a few coarse particles, while small amount of eutectics consisted of α (Al) and α AlFeSi are found in local zone in as deposited alloy. The fine particle is identified to be bcc α AlFeSi phase, and the coarse particles are monoclinic α Al 13 Fe 4 equilibrium phase, bcc α AlFeSi phase and newly found hexagonal h AlFeSi metastable phase. In α Al 13 Fe 4 , stacking faults on (100) and (001) plane and microtwin on (100) twinning plane are frequently observed. The extra reflection spots in α AlFeSi reflection pattern can be induced by α AlFeSi superstructure. The hexagonal metastable phase transforms to bcc phase, and the compositions of two phases are very similar. A close crystallographic orientation relationship between hexagonal and bcc phases are determined, and HREM image shows that the interface between them is coherent. [

Crystallographic Characteristic of Intermetallic Compounds in Al-Si-Mg Casting Alloys Using Electron Backscatter Diffraction

The Al-Si-Mg alloy which can be strengthened by heat treatment is widely applied to the key components of aerospace and aeronautics. Iron-rich intermetallic compounds are well known to be strongly influential on mechanical properties in Al-Si-Mg alloys. But intermetallic compounds in cast Al-Si-Mg alloy intermetallics are often misidentified in previous metallurgical studies. It was described as many different compounds, such as AlFeSi, Al8Fe2Si, Al5（Fe, Mn）3Si2 and so on. For the purpose of solving this problem, the intermetallic compounds in cast Al-Si alloys containing 0.5% Mg were investigated in this study. The iron-rich compounds in Al-Si-Mg casting alloys were characterized by optical microscope（OM）, scanning electron microscope（SEM）, energy dispersive X-ray spectrometer（EDS）, electron backscatter diffraction（EBSD） and X-ray powder diffraction（XRD）. The electron backscatter diffraction patterns were used to assess the crystallographic characteristics of intermetallic compounds. The compound which contains Fe/Mg-rich particles with coarse morphologies was Al8FeMg3Si6 in the alloy by using EBSD. The compound belongs to hexagonal system, space group P6_2m, with the lattice parameter a=0.662 nm, c=0.792 nm. The β-phase is indexed as tetragonal Al3FeSi2, space group I4/mcm, a=0.607 nm and c=0.950 nm. The XRD data indicate that Al8FeMg3Si6 and Al3FeSi2 are present in the microstructure of Al-7Si-Mg alloy, which confirms the identification result of EBSD. The present study identified the iron-rich compound in Al-Si-Mg alloy, which provides a reliable method to identify the intermetallic compounds in short time in Al-Si-Mg alloy. Study results are helpful for identification of complex compounds in alloys.

Synthesis of Ni/Al System Intermetallic Compound Under the Influence of Pulsating Electric Current

Synthesis of Ni/Al system intermetallic compound under the influence of pulsating electric current is researched.Reactions of Ni/Al system intermetallic compound are analyzed.It is found that solid-state reactions occur at Ni/Al interface and the main way of reactions is atoms diffusing each other under the influence of a high-density pulsating electric current.

Bonding Characteristics of the Intermetallic Compound Al_3Ti+Cr

Based on our structural model and a tight-binding Hamiltonian the eIectronic structure has been calculated by use of a recursion method (RM) for two models of the tetragonal DO22 and the cubic Ll2 crystal structures in Al3Ti+Cr for contrast, from which bonding characteristics have been discussed. The results for the interaction energy (IE) show that Cr prefers to replacing Al site. Cr partly replacing Al can change the IE between the atoms and make the constriction of lattice constant c and the elongation of lattice constant a for the DO22 and thereby may induce the change of crystal structure from DO22 to L12. The results for bond order integral (BOI) and IE between the atoms also show that the strong (110) directional Cr-Ti bondings are existed.Thus, Al3Ti-base intermetallic compounds with addition of the Cr atom still remain brittle.

APPLICATION RESEARCH ON THE Ni _3 Al INTERMETALLIC COMPOUND IN CISRI

Research work and recent progress made toward the industrial applications of the Ni_3Al in CISRI are discussed in present paper. The development of a Ni_3Al base alloy named MX-246 hardened by carbides and fine dispersion of disordered γ is summaried. This alloy,with higher peak temperature of yield strength and higher strain hardening rate than alloyIC-218,has been successfully used as the material of rolling guider at elevated temperatures and in wear conditions. The Ni3Al base alloy of GH264 has been made into welding electrodes by horizontal continuous casting process, and recently successfully surfacing welded on hydraulic blades as cavitation erosion resistance material. The process of remelting Ni3Al base alloy in air was also developed. The processes of producing welding electrodes and remelting in air set the base of industrial applications of Ni3Al in welding, repairing and casting in mass production and into components of large size. Another application of the compound, manufacturing the jet engine rivets used at about 1300℃ , can be attributed to its excellent oxidation resistance and still keeping high strength up to the melting point.

Effect of Mineral Oil on the Mechanical Properties and Fractographs of Fe_3(Al,Cr,Zr) Intermetallic Alloy

The effect of mineral oil on the mechanical properties and fractographs of Fe3(Al,Cr,Zr) in termetallic alloy has been investigated. The results show that the tensile ductility of the Fe3(Al,Cr,Zr) alloy tested in oil is comparable with the results obtained in oxygen and is in sensitive to strain rate. The fracture mode of the Fe3(Al,Cr,Zr) alloy treated at 700℃/1.5 h and tested in oil, is cleavage and with dimples in some areas.

Behavior and Mechanisms of Deformation in Intermetallic Compound Al_(66) Mn_9Ti_(25) +La

The influence of lanthanum on the microstructure, deformed behavior, microcrack susceptibility of intermetallic compound Al 66 Mn 9Ti 25 was investigated. Adding lanthanum into intermetallic compound Al 66 Mn 9Ti 25 , the lattice parameters are not changed and the Ll 2 structure is maintained. At the same time, the dendritical grain and fine second phase are obtained, which inhibits the microcrack initiation and intergranular failure. On the other hand, the movability of dislocation is enhanced and the compressive ductility is improved. The mechanism about the role of lanthanum in intermetallic compound Al 66 Mn 9Ti 25 was discussed.

不锈钢表面Al/Cu涂层制备与第一性原理计算

为了研究Al/Cu涂层中金属间化合物的生成顺序和形成机理,在304不锈钢基体表面制备了Al/Cu涂层。对试样进行热处理使得Al/Cu涂层原位反应生成金属间化合物,随后测试了涂层的高温抗氧化性能。采用第一性原理计算Al-Cu金属间化合物的焓、熵、吉布斯自由能和热容等数据。将热力学和扩散动力学相结合,提出有效生成自由能模型来预测化合物在Al/Cu界面的生成顺序。结果表明:Al/Cu涂层中首先形成Al_(2)Cu相,在Al/Cu界面处出现了AlCu相,加热时间增加至20 h后出现了富Cu的Al_(4)Cu_(9)相。由第一性原理计算得出,Al-Cu金属间化合物的形成顺序为Al_(2)Cu→AlCu→Al_(4)Cu_(9),与实验结果一致。此外,氧化实验结果表明,涂层具有良好高温抗氧化性能。