Coating of 6028 Aluminum Alloy Using Aluminum Piston Alloy and Al-Si Alloy-Based Nanocomposites Produced by the Addition of Al-Ti5-B1 to the Matrix Melt

The Al-12 pctSi alloy and aluminum-based composites reinforced with TiB₂ and Al₃Ti intermetallics exhibit good wear resistance, strength-to-weight ratio, and strength-to-cost ratio when compared to equivalent other commercial Al alloys, which make them good candidates as coating materials. In this study, structural AA 6028 alloy is used as the base material. Four different coating materials were used. The first one is Al-Si alloy that has Si content near eutectic composition. The second, third, and fourth ones are Al-6 pctSi-based reinforced with TiB₂ and Al₃Ti nano-particles produced by addition of Al-Ti5-B1 master alloy with different weight percentages (1, 2, and 3 pct). The coating treatment was carried out with the aid of GTAW process. The microstructures of the base and coated materials were investigated using optical microscope and scanning electron microscope equipped with EDX analyzer. Microhardness of the base material and the coated layer were evaluated using a microhardness tester. GTAW process results in almost sound coated layer on 6028 aluminum alloy with the used four coating materials. The coating materials of Al-12 pct Si alloy resulted in very fine dendritic Al-Si eutectic structure. The interface between the coated layer and the base metal was very clean. The coated layer was almost free from porosities or other defects. The coating materials of Al-6 pct Si-based mixed with Al-Ti5-B1 master alloy with different percentages (1, 2, and 3 pct), results in coated layer consisted of matrix of fine dendrite eutectic morphology structure inside α-Al grains. Many fine in situ TiAl₃ and TiB₂ intermetallics were precipitated almost at the grain boundary of α-Al grains. The amounts of these precipitates are increased by increasing the addition of Al-Ti5-B1 master alloy. The surface hardness of the 6028 aluminum alloy base metal was improved with the entire four used surface coating materials. The improvement reached to about 85 pct by the first type of coating material (Al-12 pctSi alloy), while it reached to 77, 83, and 89 pct by the coating materials of Al-6 pct Si-based mixed with Al-Ti5-B1 master alloy with different percentages 1, 2, and 3 pct, respectively.     

Refinement of Eutectic Si Phase in Al-5Si Alloys with Yb Additions

A series of Al-5 wt pct Si alloys with Yb additions (up to 6100 ppm) have been investigated using thermal analysis and multiscale microstructure characterization techniques. The addition of Yb was found to cause no modification effect to a fibrous morphology involving Si twinning; however, a refined plate-like eutectic structure was observed. The Al₂Si₂Yb phase was observed with Yb addition level of more than 1000 ppm. Within the eutectic Al and Si phases, the Al₂Si₂Yb phase was also found as a precipitation from the remained liquid. No Yb was detected in the α-Al matrix or plate-like Si particle, even with Yb addition up to 6100 ppm. The absence of Yb inside the eutectic Si particle may partly explain why no significant Si twinning was observed along {111}_Si planes in the eutectic Si particle. In addition, the formation of the thermodynamic stable YbP phases is also proposed to deteriorate the potency of AlP phase in Al alloys. This investigation highlights to distinguish the modification associated with the ever present P in Al alloys. We define modification as a transition from faceted to fibrous morphology, while a reduction of the Si size is termed refinement.     

Phase Structure and High-Temperature Mechanical Properties of Two-Phase Fe-25Al-xZr Alloys Compared to Three-Phase Fe-30Al-xZr Alloys

The structure and high-temperature mechanical properties of Fe-30 at. pct Al and Fe-25 at. pct Al alloys with various Zr contents are compared. The scanning electron microscope images in chemical contrast mode (R-BSE) as well as EDS, EBSD, and X-ray diffraction were used to determine the structure and phase composition. The as-cast alloys (both Fe-30Al and Fe-25Al) were observed to be two-phase DO₃/B2 + Laves phase λ ₁ (Fe,Al)₂Zr alloys with typical fine lamellar eutectic areas. During the heat treatment of the Fe-25Al alloys, their structure transformed from a DO₃/B2 matrix with fine lamellar eutectic into λ ₁ globular particles situated in a DO₃/B2 matrix. The same structure of Fe-30Al alloys decomposed into three phases: λ ₁ and τ ₁ Zr(Fe,Al)₁₂ particles in a DO₃/B2 matrix. The hardening in both groups of alloys (Fe-25Al and Fe-30Al) due to the presence of Zr-containing λ ₁ and τ ₁ phases is compared.     

Study on Microstructures of Al-4 wt pct V Master Alloys

Aluminum (Al)-V master alloys have attracted attention, because they can potentially be efficient grain refiners for wrought aluminum alloys. In this paper, the microstructure and factors affecting the microstructure of Al-4 wt pct V master alloys were investigated by means of controlled melting and casting processes followed by structure examination. The results showed that the type and morphology of the V-containing phases in Al-V master alloys were strongly affected by the temperature of the melt, concentration of vanadium in solution in the melt and the cooling conditions. Two main V-containing phases, Al₃V and Al₁₀V, which have different shapes, were found in the alloys prepared by rapid solidification. The Al₃V phase formed when there were both a high temperature (1273 K to 1673 K (1000 °C to 1400 °C)) and a relatively high vanadium content of 3 to 4 wt pct, while the Al₁₀V phase formed at a low temperature (<1373 K (1100 °C)) or a low vanadium content in the range of 1 to 3 wt pct. The results also showed that the type of V-containing phase that formed in the Al-4 wt pct V master alloy was determined by the instantaneous vanadium content.     

Electron Microscopic Study on the Suction Cast In Situ Ti-Fe-Sn Ultrafine Composites

The current investigation reports detailed study on the microstructural evolution in the suction cast hypereutectic Ti₇₁Fe_29?x Sn _x alloys during Sn addition with x = 0, 2, 2.5, 3, 3.85, 4.5, 6, and 10 at. pct and the solidification of these ternary alloys using SEM and TEM. These alloys have been prepared by melting high-purity elements using vacuum arc melting furnace under high-purity argon atmosphere. This was followed by suction casting these alloys in the water-cooled split Cu molds of diameters, ? = 1 and 3 mm, under argon atmosphere. The results indicate the formation of binary eutectic between bcc solid solution ??-Ti and B2 FeTi in all alloys. ??-Ti undergoes eutectoid transformation, ??-Ti ?? ??-Ti + FeTi, during subsequent solid-state cooling, leading to formation of hcp ??-Ti and FeTi. For alloys x < 2, the primary FeTi forms from the liquid before the formation of eutectic with minute scale Ti₃Sn phase. For alloys with 2 ?? x ?? 10, the liquid is found to undergo ternary quasi-peritectic reaction with primary Ti₃Sn, L+Ti₃Sn ?? ??-Ti+FeTi, leading to formation of another kind of FeTi. In all the other alloy compositions (3.85 ?? x ?? 10), Ti₃Sn and FeTi dendrites are observed in the suction cast alloys with profuse amount of Ti₃Sn being formed for alloys with x ?? 4.5. The current study conclusively proves that the liquid undergoes ternary quasi-peritectic reaction involving four phases, L + Ti₃Sn ?? ??-Ti + FeTi, which lies at the invariant point Ti_69.2±0.8Fe_27.4±0.7Sn_3.4±0.2 (denoted by P). Below P, there is one univariant reaction, i.e., L ?? ??-Ti + FeTi for all alloy compositions, whereas above P, liquid undergoes one of the univariant reactions, i.e., L + ??-Ti ?? Ti₃Sn (Sn = 2, 2.5, 3, and 4.5 at. pct) or L + FeTi ?? Ti₃Sn for alloys (Sn = 6, 10 at. pct). For alloy with Sn = 3.85 at. pct, the ternary quasi-peritectic reaction is co-operated by two monovariant eutectic reactions, i.e., L ?? ??-Ti + FeTi below P and L ?? FeTi + Ti₃Sn above P. Detailed microstructural information allows us to construct liquidus projection of the investigated alloys. The results are critically discussed in the light of available literature data.     

Effect of Zr Addition on Microstructure and Properties of FeCrNiMnCoZr x and Al0.5FeCrNiMnCoZr x High Entropy Alloys

In this study, the effect of Zr addition on phase formation, microstructure, and hardness of FeCrNiMnCoZr _x and Al_0.5FeCrNiMnCoZr _x were investigated. High entropy alloys (HEA) were synthesized using arc melting technique in argon (Ar) atmosphere (x = 0, 0.1, 0.2, 0.3). Ingots were homogenized for 24 h at 900 °C in Ar atmosphere. Phase formation, microstructure and hardness of HEAs were investigated using field emission scanning electron microscope, X-ray diffraction and Vickers microhardness tester. Electron micrographs of HEAs showed majorly dendritic(DR) and interdendritic(ID) phases. For both FeCrNiMnCoZr _x and Al_0.5FeCrNiMnCoZr _x alloys, amount of ID phases is seen to increase with increased Zr content. Aluminium containing HEAs showed fine needle-shaped precipitates dispersed throughout the matrix phase. XRD results confirmed the presence of mixed FCC/BCC phases in FeCrNiMnCoZr _x alloys and BCC as majority phase in Al_0.5FeCrNiMnCoZr _x alloys. As the Zr content increased, hardness of HEA increased.     

Magnesium silicide intermetallic alloys

Methods of induction melting an ultra-low-density magnesium silicide (Mg₂Si) intermetallic and its alloys and the resulting microstructure and microhardness were studied. The highest quality ingots of Mg₂Si alloys were obtained by triple melting in a graphite crucible coated with boron nitride to eliminate reactivity, under overpressure of high-purity argon (1.3 X 10⁵ Pa), at a temperature close to but not exceeding 1105 °C ± 5 °C to avoid excessive evaporation of Mg. After establishing the proper induction-melting conditions, the Mg-Si binary alloys and several Mg₂Si alloys macroalloyed with 1 at. pct of Al, Ni, Co, Cu, Ag, Zn, Mn, Cr, and Fe were induction melted and, after solidification, investigated by optical microscopy and quantitative X-ray energy dispersive spectroscopy (EDS). Both the Mg-rich and Si-rich eutectic in the binary alloys exhibited a small but systematic increase in the Si content as the overall composition of the binary alloy moved closer toward the Mg₂Si line compound. The Vickers microhardness (VHN) of the as-solidified Mg-rich and Si-rich eutectics in the Mg-Si binary alloys decreased with increasing Mg (decreasing Si) content in the eutectic. This behavior persisted even after annealing for 75 hours at 0.89 pct of the respective eutectic temperature. The Mg-rich eutectic in the Mg₂Si + Al, Ni, Co, Cu, Ag, and Zn alloys contained sections exhibiting a different optical contrast and chemical composition than the rest of the eutectic. Some particles dispersed in the Mg₂Si matrix were found in the Mg₂Si + Cr, Mn, and Fe alloys. The EDS results are presented and discussed and compared with the VHN data. Formerly Formerly     

Nonequilibrium Solidification Behavior of Co-Si Alloys Near the First Eutectic Point

Adopting a fluxing purification and cyclic superheating technique, Co-10 wt pct Si and Co-15 wt pct Si alloys had been undercooled to realize rapid solidification in this work. It was investigated that the solidification modes and microstructures of Co-Si alloys were deeply influenced by the undercooling of the melts. Both alloys solidified with a near-equilibrium mode in a low undercooling range; the peritectic reaction occurred between the primary phase and the remnant liquids, and it was followed by the eutectic reaction and eutectoid transformation. With the increase of undercooling, both alloys solidified with a nonequilibrium mode, and the peritectic reaction was restrained. As was analyzed, a metastable Co₃Si phase was found in Co-10 wt pct Si alloy when a critical undercooling was achieved.     

Phase relationships in the Al-Ta system

Phase relationships have been investigated in the Al-Ta system in the region between Al and AlTa₂. Al-Ta alloys with compositions between 20 and 60 at. pct Ta were prepared using different processing routes. Following appropriate heat treatments, the alloys were characterized microstructurally, by quantitative electron probe microanalyses, X-ray diffraction, and differential thermal analysis. Based on our observations, a revised Al-Ta phase diagram is proposed. Significant revisions include the verification of Al₃Ta as a line compound, the absence of a eutectic transformation in the region between Al₃Ta and AlTa₂, and the conclusive identification of a phase designated as AlTa near the equiatomic composition.     

Cr-Ge-Si Alloys for High-Temperature Structural Applications: Microstructural Evolution

The microstructural evolution of Cr-Si_1?x -Ge _x (0 < x < 15 at. pct) alloys was studied (in annealed state). The quasi-isothermal section of the ternary diagram was assessed by quantitative EPMA analysis. Morphology, phase formation, chemical distribution, and indentation hardness of the alloys were investigated as a function of Ge/Si ratio. The microstructure of all studied alloys consisted of Cr_ss solid solution and A15 Cr₃X intermetallic phases. Substitution of Si by Ge strongly altered the microstructure by transforming the morphology from a lamellar eutectic Cr-Cr₃Si system toward a peritectic one with dispersed Cr_ss phase in A15 matrix. EPMA chemical distribution maps and X-ray diffraction results prove the mutual solubility of Si and Ge in A15 phase by forming Cr₃(Si,Ge) as a complex A15 structure with Cr₃(Si_1?x Ge _x ) composition. Precipitates of the intermetallic phase within the Cr_ss phase was observed in Ge-alloyed samples. Indentation hardness results showed that upon Si-Ge substitution the hardness of both phases was reduced. However, Si substitution by Ge had a stronger influence on the hardness of the solid solution phase than on the intermetallic phase.     

High-Temperature Mechanical Behavior of Extruded Mg-Y-Zn Alloy Containing LPSO Phases

The high-temperature mechanical behavior of extruded Mg_97?3x Y_2x Zn _x (at. pct) alloys is evaluated from 473 K to 673 K (200 °C to 400 °C). The microstructure of the extruded alloys is characterized by Long Period Stacking Ordered structure (LPSO) elongated particles within the magnesium matrix. At low temperature and high strain rates, their creep behavior shows a high stress exponent (n = 11) and high activation energy. Alloys behave as a metal matrix composite where the magnesium matrix transfers part of its load to the LPSO phase. At high-temperature and/or low stresses, creep is controlled by nonbasal dislocation slip. At intermediate and high strain rates at 673 K (400 °C) and at intermediate strain rates between 623 K and 673 K (350 °C and 400 °C), the extruded alloys show superplastic deformation with elongations to failure higher than 200 pct. Cracking of coarse LPSO second-phase particles and their subsequent distribution in the magnesium matrix take place during superplastic deformation, preventing magnesium grain growth.     

Influence of Extrusion on the Microstructure and Mechanical Behavior of Mg-9Li-3Al-xSr Alloys

Mg-9Li-3Al-xSr (LA93-xSr, x = 0, 1.5, 2.5, and 3.5 wt pct) alloys were cast and extruded at 533 K (260 °C) with an extrusion ratio of 28. The microstructure and mechanical response are reported and discussed paying particular attention to the influence of extrusion and Sr content on phase composition, strength, and ductility. The results of the current study show that LA93-xSr alloys contain both α-Mg (hcp) and β-Li (bcc) matrix phases. Moreover, the addition of Sr refines the grain size in the as-cast alloys and leads to the formation of the intermetallic compound (Al₄Sr). Our results show significant grain refinement during extrusion and almost no influence of Sr content on the grain size of the extruded alloys. The microstructure evolution during extrusion is governed by continuous dynamic recrystallization (CDRX) in the α-Mg phase, whereas discontinuous dynamic recrystallization (DDRX) occurs in the β-Li phase. The mechanical behavior of the extruded LA93-xSr alloy is discussed in terms of grain refinement and dislocation strengthening. The tensile strength of the extruded alloys first increases and then decreases, whereas the elongation decreases monotonically with increasing Sr; in contrast, hardness increases for all Sr compositions studied herein. Specifically, when Sr content is 2.5 wt pct, the extruded Mg-9Li-3Al-2.5Sr (LAJ932) alloy exhibits a favorable combination of strength and ductility with an ultimate tensile strength of 235 MPa, yield strength of 221 MPa, and an elongation of 19.4 pct.     

Microstructure and ordering of L12 titanium trialuminides

The present article reports and discusses the results of the microstructural characterization of various modifications of Ll₂ trialuminides containing various titanium contents, including the first ever report on their degree of ordering. The Ll₂ trialuminide alloys Al₃Ti + X, where X = Cu, Fe, Cr, and Mn were studied. The as-cast structure contains a very low level of porosity, and the amount of second phase depends on the particular alloy. After homogenization, the second phase is reduced in almost all the alloys to the level less than 0.5 pct, except for the Mn-high Ti alloy in which it remains at about 20 pct and its composition is 67.9 ± 0.6 at. pct Al, 2.2 ± 0.6 at. pct Mn, and 29.9 ± 0.3 at. pct Ti. In almost all the alloys, porosity after homogenization increases about twofold, except in the Al₃Ti + Cr alloy in which it remains at almost the as-cast level. Limited transmission electron microscopic observations have revealed the existence of very fine (≈10 nm) unidentified precipitates in the homogenized Al₃Ti + Cu alloy. The homogenized Al₃Ti + Cr and Mn alloys have greater lattice parameters than the Al₃Ti + Fe and Cu alloys. It is also found that the long-range order parameterS of the ho- mogenized Ll₂ Al₃Ti + X alloys dramatically decreases with increasing titanium content.     

Structural Features of Al–Hf–Sc Master Alloys

Microstructural features of new master alloys of the Al–Hf–Sc system with metastable aluminides with a cubic lattice identical to the lattice of a matrix of aluminum alloys are investigated using optical microscopy, scanning electron microscopy, and electron probe microanalysis. Binary and ternary alloys are smelted in a coal resistance furnace in graphite crucibles in argon. Alloys Al–0.96 at % Hf (5.98 wt % Hf) and Al–0.59 at % Hf (3.77 wt % Hf) are prepared with overheating above the liquidus temperature of about 200 and 400 K, respectively. Alloys are poured into a bronze mold, the crystallization rate in which is ~10³ K/s. Metastable Al₃Hf aluminides with a cubic lattice are formed only in the alloy overheated above the liquidus temperature by 400 K. Overheating of ternary alloys, in which metastable aluminides Al _n (Hf_1–xSc _x ) formed, is 240, 270, and 370 K. Depending on the Hf-to-Sc ratio in the alloy, the fraction of hafnium in aluminides Al _n (Hf_1–xSc _x ) varies from 0.46 to 0.71. Master alloys (at %) Al–0.26Hf–0.29Sc and Al–0.11Hf–0.25Sc (wt %: Al–1.70Hf–0.47Sc and Al–0.75Hf–0.42Sc) have a fine grain structure and metastable aluminides of compositions Al _n (Hf_0.58Sc_0.42) and Al _n (Hf_0.46Sc_0.54), respectively. Sizes of aluminides do not exceed 12 and 7 μm. Their lattice mismatch with a matrix of aluminum alloys is smaller than that for Al₃Sc. This makes it possible to assume that experimental Al–Hf–Sc master alloys manifest a high modifying effect with their further use. In addition, the substitution of high-cost scandium with hafnium in master alloys can considerably reduce the consumption of the latter.     

Microstructural Evolution and Solidification Behavior of Al-Mg-Si Alloy in High-Pressure Die Casting

Microstructural evolution and solidification behavior of Al-5 wt pct Mg-1.5 wt pct Si-0.6 wt pct Mn-0.2 wt pct Ti alloy have been investigated using high-pressure die casting. Solidification commences with the formation of primary α-Al phase in the shot sleeve and is completed in the die cavity. The average size of dendrites and fragmented dendrites of the primary α-Al phase formed in the shot sleeve is 43 μm, and the globular primary α-Al grains formed inside the die cavity is at a size of 7.5 μm. Solidification inside the die cavity also forms the lamellar Al-Mg₂Si eutectic phase and the Fe-rich intermetallics. The size of the eutectic cells is about 10 μm, in which the lamellar α-Al phase is 0.41 μm thick. The Fe-rich intermetallic compound exhibits a compact morphology and is less than 2 μm with a composition of 1.62 at. pct Si, 3.94 at. pct Fe, and 2.31 at. pct Mn. A solute-enriched circular band is always observed parallel to the surface of the casting. The band zone separates the outer skin region from the central region of the casting. The solute concentration is consistent in the skin region and shows a general drop toward the center inside the band for Mg and Si. The peak of the solute enrichment in the band zone is much higher than the nominal composition of the alloy. The die casting exhibits a combination of brittle and ductile fracture. There is no significant difference on the fracture morphology in the three regions. The band zone is not significantly detrimental in terms of the fracture mechanism in the die casting. Calculations using the Mullins and Sekerka stability criterion reveal that the solidification of the primary α-Al phase inside the die cavity has been completed before the spherical α-Al globules begin to lose their stability, but the α-Al grains formed in the shot sleeve exceed the limit of spherical growth and therefore exhibit a dendritic morphology.     

Effect of Ca and Rare Earth Additions on the Texture,Microhardness, Microstructure and Structural Properties of As-Cast Mg–4Al–2Sn Alloys

In this work, alloys with nominal composition of Mg–4Al–2Sn–xRE–yCa (where RE = rare earth, x = 0, 1, 3 and y = 0, 1) have been prepared using tilt casting method. Prepared as-cast samples have been investigated by X-ray diffractometry, optical microscopy and scanning electron microscopy techniques as well as hardness measurement. The texture, microstructure and structural parameters of samples were also refined from X-ray diffraction patterns utilizing the Rietveld method and generalized spherical-harmonic model. It was found that with addition of rare earth and calcium elements, intermetallic phases of γ-Mg₁₇Al₁₂ and β-Mg₂Al₃ disappeared in cast alloys while small amount of Al₁₁RE₃ and CaMgSn intermetallics phases are formed. The texture factor of α-Mg as a main phase of samples was decreased with addition of rare earth up to 1 % and increased with more addition of rare earth elements. According to the results, with addition of rare earth elements, texture of Mg phase changes from 〈112〉 direction to 〈100〉 and 〈002〉 directions while Ca addition causes the texture in 〈002〉 direction. The microhardness of Mg–4Al–2Sn alloy was enhanced with addition of rare earth and calcium elements which is in agreement with the expected trend based on computed phase fraction of the samples. Addition of 1 wt% of calcium causes a dramatic change in the morphology and chemical composition of intermetallic phases, from acicular shape with composition of Al₁₁RE₃ into fine feather of CaMgSn intermetallic phase which accumulated in cluster morphologies in interdendritic regions.     

The Effect of Minor Addition of Ni on the Microstructural Evolution and Mechanical Properties of Suction Cast Al-0.14 at. pct Sc Binary Alloy

Aluminum scandium binary alloys represent a promising precipitation-hardening alloy system. However, the hardness of the binary alloys decreases with the rapid coarsening of Al₃Sc precipitate during high-temperature aging. In the current study, we report a new approach to compensate for the loss of mechanical properties by combining rapid solidification with very small ternary addition of transition metal Ni. This addition yields dispersion, and at a critical concentration improves the mechanical properties. We explore additions of a maximum of 0.06 at. pct of Nickel to a binary Al-0.14 at. pct Sc alloy, which yield nickel-rich dispersions. We report two kinds of biphasic dispersions containing AlNi₂Sc/Al₉Ni₂ and α-Al/Al₉Ni₂ phase combinations. The maximum improvement in mechanical properties occurs with the addition of 0.045 at. pct Ni with a yield strength of 239 ± 7 MPa for an aging treatment at 583 K (310 °C) for 15 hours.     

Influence of Phosphorus on the Nucleation of Eutectic Silicon in Al-Si Alloys

The role of phosphorus (P) in the heterogeneous nucleation of eutectic silicon (Si) and the evolution of eutectic grains in hypoeutectic aluminum-silicon alloys were investigated. Systematic additions of P in the range of 0.5 to 20 ppm to Al-7 wt pct Si alloys of different purities have shown that the morphology of the eutectic Si changes from a fine plate- to a coarse flake-like structure. The growth of eutectic grains was investigated by interrupting the eutectic reaction by quenching experiments. Moreover, the macroscopic growth mode of the eutectic grains was characterized by electron backscatter diffraction. An increase in P concentration from 2 to 3 ppm resulted in a transition of the macroscopic growth mode of the Al-Si eutectic in high purity alloys from growth with a planar front with a strong dependence of the thermal gradient, to nucleation in the vicinity of the primary Al dendrites and subsequent growth of distinct eutectic grains. It is suggested that AlP particles are the key impurities acting as potential nucleation sites for eutectic Si. This is further substantiated as with increasing P concentration nucleation and growth of the Al-Si occurred at higher temperatures close the equilibrium Al-Si eutectic solidification temperature at 850 K (577 °C). In addition, the recalescence undercooling ΔT _R,eu was reduced from 4.5 K (0.5 ppm P) to 1.5 K (20 ppm P) in high purity alloys. This was accompanied by a drastic increase of the nucleation rate of the eutectic grains.     

Interfacial Reaction Between CaO-SiO2-MgO-Al2O3 Flux and Fe-xMn-yAl (x = 10 and 20 mass pct, y = 1, 3, and 6 mass pct) Steel at 1873 K (1600 °C)

This study investigated the interfacial reaction kinetics and related phenomena between CaO-SiO₂-MgO-Al₂O₃ flux and Fe-xMn-yAl (x = 10 and 20 mass pct, y = 1, 3, and 6 mass pct) steel, which simulates transformation-induced plasticity (TRIP) and twinning-induced plasticity (TWIP) steels at 1873 K (1600 °C). It also examines the effect of changes in the composition of the steel and slag phases on the interfacial reaction rate and the reaction mechanisms. The content of Al and Si in the 1 mass pct Al-containing steel was found to change rapidly within the first 15 minutes of the reaction, but then it remained relatively constant. The content of Al and Si in the 3 to 6 mass pct Al-containing steels, in contrast, changed continuously throughout the entire reaction time. In addition, the content of Mn in the 1 mass pct Al-containing steels initially decreased with increasing time, but the content did not change in the 3 to 6 mass pct Al-containing steels. Furthermore, the mass transfer coefficient of Al, k _Al, in the 1 mass pct Al-containing systems was significantly higher than that in other systems; i.e., the k _Al can be arranged such that 1 mass pct Al systems >> 3 mass pct Al systems ≥ 6 mass pct Al systems. The compositions of the final slags were close to the saturation lines of the [Mg,Mn]Al₂O₄ and MgAl₂O₄ spinels when the slags reacted with 1 mass pct Al and 3 to 6 mass pct Al-containing steels, respectively. These results, which show the effect of Al content on the reaction phenomena, can be explained by the significant increase in the apparent viscosity of the slags that reacted with the 3 to 6 mass pct Al-containing steels. This reaction was likely caused by the precipitation of solid compounds such as MgAl₂O₄ spinel and CaAl₄O₇ grossite at locally alumina-enriched areas in the slag phase. This analysis is in good accordance with the combination of Higbie’s surface renewal model and the Eyring equation.