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Corrosion Behavior of FeAl and Fe3Al Based Fe-Al-C Alloys in Sulfuric Acid

A.P. Silva P.P. Brito N. Martins
Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 77-82 | DOI: 10.24425/afe.2022.140228
Keywords Iron Aluminides Microstructure Mechanical properties corrosion resistance
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Abstract

Iron aluminides are iron-aluminum alloys that have excellent resistance to oxidation at high temperatures with low density, high resistance/weight ratio and a low manufacturing cost. Due to its characteristics, these alloys are presented as an option to replace stainless steels in certain applications. This works intends report the casting process and subsequent analyses involving microstructure, mechanical properties, and corrosion resistance of two Fe-Al-C alloys (Fe-11wt%Al and Fe-25wt%Al, containing 0.31-0.37%C), which were prepared in an induction furnace and poured in a permanent mold. Samples of these alloys were characterized and presented elevated hardness values of 37 HRC (alloy Fe-11wt%Al) and 49.6HRC (alloy Fe-25wt%Al) and microstructure with aluminides type Fe3Al and FeAl and also carbides type K. The Fe-11wt%Al alloy exhibited superior resistance to uniform corrosion, although both Fe-Al-C alloys exhibited significantly higher corrosion rates compared to a binary iron aluminide in 0.5M H2SO4 containing naturally dissolved oxygen.
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Bibliography

[1] Zamanzade, M., Barnoush, A. & Motz, C. (2016). A review on the properties of iron aluminide intermetallics. Crystals. 6(10), 1-29. DOI: 10.3390/cryst6010010.
[2] Stoloff, N.S. (1998). Iron aluminides: present status and future prospects. Materials Science and Engineering: A. 258(1-2), 1-14. DOI: 10.1016/S0921-5093(98)00909-5.
[3] Cinca, N., Lima, C.R.C. & Guilemany, J.M. (2013). An overview of intermetallics research and application: Status of thermal spray coatings. Journal of Materials Research and Technology. 2(1), 75-86. DOI: 10.1016/j.jmrt.2013.03.013.
[4] Palm, M., Stein, F. & Dehm, G. (2019). Iron Aluminides. Annual Review of Materials Research. 49, 297-326. DOI: 10.1146/annurev-matsci-070218-125911.
[5] Deevi, S.C. & Sikka, V.K. (1996). Nickel and iron aluminides: an overview on properties, processing, and applications. Intermetallics. 4(5) 357-375. DOI: 10.1016/0966-9795(95)00056-9.
[6] Shankar Rao, V., Baligidad, R. G. & Raja, V. S. (2002). Effect of carbon on corrosion behaviour of Fe3Al intermetallics in 0.5N sulphuric acid. Corrosion Science. 44, 521-533. DOI: 10.1016/S0010-938X(01)00084-1.
[7] Shankar Rao, V. (2005). Repassivation behaviour and surface analysis of Fe3Al based iron aluminide in 0.25M H2SO4. Corrosion Science. 47, 183-194. DOI: 10.1016/j.corsci.2004.05.014.
[8] Nigam, A.K., Balasubramaniam, R., Bhargava, S. & Baligidad, R.G. (2006). Electrochemical impedance spectroscopy and cyclic voltammetry study of carbon-alloyed iron aluminides in sulfuric acid. Corrosion Science. 48(7), 1666-1678. DOI: 10.1016/j.corsci.2010.05.006.
[9] Schneider, A., Falat, L., Sauthoff, G. & Frommeyer, G. (2005). Microstructures and mechanical properties of Fe3Al-based Fe-Al-C alloys. Intermetallics. 13(12), 1322-1331. DOI: 10.1016/j.intermet.2005.01.0.
[10] Brito, P., Pinto, H., Klaus, M., Genzel, C. & Kaysser-Pyzalla, A. (2010). Internal stresses and textures of nanostructured alumina scales growing on polycrystalline Fe3Al alloy. Powder Diffraction. 25(2), 114-118. DOI: 10.1154/1.3402764
[11] Brito, P., Schuller, E., Silva, J., Campos, T.R., Araújo, C.R. & Carneiro, J.R. (2017). Electrochemical corrosion behaviour of (100), (110) and (111) Fe3Al single crystals in sulphuric acid. Corrosion Science. 126, 366-373. DOI: 10.1016/j.corsci.2017.05.029.
[12] Brito, P.P., Carvalho Filho, C.T. & Oliveira, G.A. (2020). Electrochemical corrosion behavior of iron aluminides in sulfuric acid. Materials Science Forum. 1012, 395-400. DOI: 10.4028/www.scientific.net/MSF.1012.395.
[13] Hernández-Hernández, M., Liu, H. B., Alvarez-Ramirez, J. & Espinosa-Medina, M. A. (2017). Corrosion behavior of Fe-40at.%Al-Based intermetallic in 0.25M H2SO4 solution. Journal of Materials Engineering and Performance. 26, 5983-5996. DOI: 10.1007/s11665-017-3036-5.

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Authors and Affiliations

A.P. Silva
1
ORCID: ORCID
P.P. Brito
1
N. Martins
1
  1. PUC Minas, Brazil

High Temperature Corrosion Performance of Carbon Steel Coated with Iron Aluminide in Mixture of O2 and SO2 Atmosphere

P. Omranian-Mohammadi R. Raiszadeh H.R. Shahversdi
Archives of Metallurgy and Materials | 2020 | vol. 65 | No 2 | 529-538 | DOI: 10.24425/amm.2020.132790
Keywords iron aluminide high temperature corrosion plain carbon steel
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Abstract

In this investigation the surface of an aluminized sample of plain carbon steel was melted and alloyed using a tingsten inert gas (TIG) welding process to produce iron-aluminide intermetallic phases on the surface. The produced coating was then characterized by SEM and EDS and its high-temperature properties in O2 + 1%SO2 gas were examined. The results showed that the Fe3Al coating produced could protect the substrate as it was subjected to the corroding gases at 700oC due to the formation of an alumina layer between the substrate and an outer layer of Fe2O3. At 900oC, the coating could only protect the substrate for 64 h. The lack of further protection at this temperature is attributed to the decrease in the protective properties of alumina with an increase in its temperature and the lack of presence of enough Al atoms in the coating for the repair of the defects formed in the alumina layer.

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Authors and Affiliations

P. Omranian-Mohammadi
R. Raiszadeh
H.R. Shahversdi

Mechanical Alloying Synthesis and Spark Plasma Sintering Consolidation of Al-Ti-Si-W Alloys

Bum-Soon Park Jae-Cheol Park Hyun-Kuk Park Jeong-Han Lee
Archives of Metallurgy and Materials | 2024 | vol. 69 | No 1 | 25-28 | DOI: 10.24425/amm.2024.147778
Keywords Titanium aluminide alloys mechanical alloying spark plasma sintering mechanical property
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Abstract

Al-Ti-Si-W quaternary powders were mechanically synthesized by planetary ball milling; and further consolidated by spark plasma sintering. The nominal compositions of the quaternary alloys were designed to be Al60Ti30Si5W5 and Al45Ti40Si10W5 (wt.%). The microstructural evolution of intermetallic compounds in Al-Ti-Si-W alloys included titanium aluminide, titanium silicide, and ternary alloys (AlxTiy, TixSiy, and TixAly,Siz), whereas W was embedded in the Al-Ti matrix as a single phase. The phase composition and grain size distribution were investigated using electron backscatter diffraction analysis, in which refined and uniform microstructures (less than 0.3 μm) were attributed to severe plastic deformation and rapid densification of the pre-alloyed powders. The mechanical properties were correlated with the Al content in the quaternary alloys; a high hardness of 1014.6 ±73.5 kg/mm2 was observed.
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Authors and Affiliations

Bum-Soon Park
1
Jae-Cheol Park
1
ORCID: ORCID
Hyun-Kuk Park
2
ORCID: ORCID
Jeong-Han Lee
3
ORCID: ORCID
  1. Korea Institute of Industrial Technology, Automotive Materials & Component R&D Group, 6, Cheomdan-gwagiro 208-gil, Buk-gu, Gwangju, 61012, Korea
  2. Korea Institute of Industrial Technology, Automotive Materials & Component R&D Group, 6, Cheomdan-gwagiro 208-gil, Buk-gu, Gwangju, 61012, Koreaqqq
  3. Korea Institute of Industrial Technology, Advanced Energy Materials and Components R&D Group, 33-1, Jungang-ro, Yangsan, Gyeongsangnam-do, 50623, Korea

Analysis of Structure and Abrasion Resistance of the Metal Composite Based on an Intermetallic FeAl Phase with VC and TiC Precipitates

D. Kopyciński E. Guzik R. Gilewski A. Szczęsny J. Dorula
Archives of Foundry Engineering | 2013 | No 3 | DOI: 10.2478/afe-2013-0058
Keywords Aluminium cast iron Al4C3 TiC VC Intermetallic FeAl Iron aluminides
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Abstract

Metal alloys with matrix based on an Fe-Al system are generally considered materials for high-temperature applications. Their main advantages are compact crystallographic structure, long-range ordering and structural stability at high temperatures. These materials are based on an intermetallic phase of FeAl or Fe3Al, which is stable in the range from room temperature up to the melting point of 1240°C. Their application at high temperatures is also beneficial because of the low cost of production, very good resistance to oxidation and corrosion, and high mechanical strength. The casting alloy the structure of which includes the FeAl phase is, among others, highaluminium cast iron. This study has been devoted to the determination of the effect of vanadium and titanium on the transformation of the high-aluminium cast iron structure into an in-situ FeAl-VC composite.
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Authors and Affiliations

D. Kopyciński
E. Guzik
R. Gilewski
A. Szczęsny
J. Dorula

The Structure of High-Quality Aluminium Cast Iron

D. Kopyciński E. Guzik A. Szczęsny R. Gilewski
Archives of Foundry Engineering | 2012 | No 1 | DOI: 10.2478/v10266-012-0010-4
Keywords Aluminium cast iron Al4C3 TiC VC Intermetallic FeAl Iron aluminides
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Abstract

This study presents an analysis of aluminium cast iron structure (as-cast condition) which are used in high temperatures. While producing casts of aluminium iron, the major influence has been to preserve the structure of the technological process parameters. The addition of V, Ti, Cr to an Fe-C-Al alloy leads to the improvement of functional and mechanical cast qualities. In this study, a method was investigated to eliminate the presence of undesirable Al4C3 phases in an aluminium cast iron structure and thereby improve the production process. V and Ti additions to aluminium cast iron allow the development of FeAl - VC or TiC alloys. In particular, V or Ti contents above 5 wt.% were found to totally eliminate the presence of Al4C3. In addition, preliminary work indicates that the alloy with the FeAl - VC or TiC structure reveals high oxidation resistance. The introduction of 5 wt.% chromium to aluminium cast iron strengthened the Al4C3 precipitate. Thus, the resultant alloy can be considered an intermetallic FeAl matrix strengthened by VC and TiC or modified Al4C3 reinforcements.

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
R. Gilewski

Application Of Artificial Neural Network for Prediction of the Cyclic Oxidation Behavior of Electrical Resistance Sintered Gamma-TiAl Intermetallics

Y. Garip Z. Garip O. Ozdemir
Archives of Metallurgy and Materials | 2021 | vol. 66 | No 2 | 581-591 | DOI: 10.24425/amm.2021.135895
Keywords TiAl Artificial neural networks Oxidation kinetics Electrical resistance sintering Aluminides
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Abstract

TiAl based intermetallics are widely used for structural applications in aviation, chemical engineering, automotive and sports equipment. In this study, the electrical resistance sintering (ERS) technology used in the production of gamma-TiAl intermetallics is based on the principle of applying pressure simultaneously with a high-density electric current. The purpose of this study was to investigate the cyclic oxidation resistance of Ti-44Al-3Mo and Ti-44Al-3Nb alloys (at.%) and the applicability of artificial neural network (ANN) modeling for the forecast of the oxidation behavior of these alloys. In order to obtain this aim, the alloys sintered by ERS were oxidized at 900°C for 360 h and then the oxidation behaviors of them are evaluated by plotting a graph between weight change as a function of time. The data collected after the oxidation experiments were used to construct the prediction models. The modelling results show that a good agreement between experimental results and prediction results was found. The oxidized alloys were characterized using XRD and SEM-EDS. The XRD patterns revealed the oxidation products are composed of TiO2 and Al2O3 oxides. SEM-EDS analysis indicated that the oxide scales of alloys are made up of a multilayered structure.
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Authors and Affiliations

Y. Garip
1
ORCID: ORCID
Z. Garip
2
ORCID: ORCID
O. Ozdemir
1
ORCID: ORCID
  1. Sakarya Applied Science University, Technology Faculty , Department of Metallurgy and Materials Engineering, Esentepe Campus, 54187, Sakarya -Turkey
  2. Sakarya Applied Science University, Technology Faculty, Department of Computer Engineering, Esentepe Campus, 54187, Sakarya -Turkey

State of Strain and Development of Microstructure of 22MnB5 Steel and Al-Si Coating During Deep Drawing of Automotive B Pillar

M. Paćko J. Krawczyk T. Śleboda T. Frocisz Maciej Rumiński O. Lypchanskyi T. Tokarski P. Piasecki
Archives of Metallurgy and Materials | 2021 | vol. 66 | No 2 | 601-608 | DOI: 10.24425/amm.2021.135897
Keywords B pillar 22MnB5 steel aluminide coating deep drawing hot stamping
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Abstract

The analysis of the development of the microstructure of deep drawn automotive B pillar, as well as the analysis of deformation based on numerical simulation and experiment, was performed. The microstructure of steel sheet as well as Al-Si coating after various stages of B pillar production was investigated. It was found that the obtained microstructure of the B pillar was significantly different from that described in many studies as a proper one. The microstructure of the investigated material consisted of martensite, bainite, and a small amount of ferrite. Al-Si coating, despite its morphological changes, remained on the surface of B pillar and, in spite of this, did not fully eliminate oxidation and decarburization of B pillar material. The analysis of the state of strain allowed to evaluate the deformation safety of the process, as well as to verify the simulation results through measurements of sheet thickness variations.
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Authors and Affiliations

M. Paćko
1
ORCID: ORCID
J. Krawczyk
1
ORCID: ORCID
T. Śleboda
1
ORCID: ORCID
T. Frocisz
1
ORCID: ORCID
Maciej Rumiński
ORCID: ORCID
O. Lypchanskyi
1
T. Tokarski
1
ORCID: ORCID
P. Piasecki
2
  1. AGH University of Science and Technology, Al. Mickiewicza 30, 30-059 Krakow, Poland
  2. Kirchhoff Automotive, Mielec, Poland

Electronic structure, stability, and strength of Cu–NiAl alloys: Experiment and DFT investigation

Zakaryaa Zarhri
Opto-Electronics Review | 2022 | 30 | 2 | e141707 | DOI: 10.24425/opelre.2022.141707
Keywords mechanical properties electronic structure DFT study Cu-doped nickel aluminide formation energy
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Abstract

In this study, the copper doping effect on the NiAl structural stability, strength, and electronic structure was investigated. The samples were prepared using induction melting at 2073 K. This material presents good mechanical and physical properties such as high-temperature strength, fatigue or impact, and corrosion resistance which meet technical requirements of many applications. The microstructure of the Cu-doped nickel aluminide was studied using a metallurgical microscope and its lattice parameter was also studied and characterized using an X-ray diffractometer for different concentrations of Cu. The lattice constant of the existing phases was calculated, and it was found that the lattice distortion and gamma prime phase energy have high values allowing the increase of the entropy term of the alloy and subsequently increasing its hardness. From the ab-initio calculation, it was determined that the Cu atoms have the Al sites as a preferred site and prefer to bond with Ni atoms which leads to the improvement of the material hardness. Ab-initio density functional theory was applied to study the formation energy that revealed increasing with Cu amount.
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Authors and Affiliations

Zakaryaa Zarhri
1
ORCID: ORCID
  1. CONACYT-Tecnológico Nacional de México/I.T. Chetumal; Insurgentes 330, C.P. 77013, Chetumal, Quintana Roo, Mexico

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