Hot dip aluminizing (HDA) is an effective way to improve the high temperature corrosion resistance and scaling resistance of ferrous materials. The formation of intermetallic compound layers between the two materials is a dominant factor in determining the properties of hot dip aluminized steel. The formation behavior of the intermetallic compound layer between a Si alloyed Al melt and cast iron has been investigated.The thickness of the intermetallic compound layer was significantly reduced as a result of the increased carbon content of the cast iron matrix. The thickness of the intermetallic compound layer formed in the Al-Si-Fe three-component alloy system remains constant in the early stage of the reaction, and it becomes increasingly rough with increased reaction time. The increased roughness could be attributed to the increased Fe concentration in the Al-Si melt near the cast iron surface, which is a result of the increased inter-diffusion of Al, Si and Fe atoms with increased reaction time by which the formation, melting and spallation of the intermetallic compound layer is enhanced.KEY WORDS: hot dip aluminizing; cast iron; intermetallic compound layer; silicon effect; carbon effect.
Hot dip aluminizing (HDA) is widely used in industry for improving corrosion resistance of material. The formation of intermetallic compound layers during the contact between dissimilar materials at high temperature is common phenomenon. Generally, intermetallic compound layers of Fe 2 Al 5 and FeAl 3 are formed at the Al alloy and Fe substrate interface. In case of cast iron, high contact angle of graphite existed in the matrix inhibits the formation of intermetallic compound layer, which carry with it the disadvantage of a reduced reaction area and mechanical properties. In present work, the process for the removal of graphite existed on the surface of specimen has been investigated. And also HDA was proceeded at 800 o C for 3 minutes in aluminum alloy melt. The efficiency of graphite removal was increased with the reduction of particle size in sanding process. Graphite appears to be present both in the region of melting followed by re-solidification and in the intermetallic compound layer, which could be attributed to the fact that the surface of cast iron is melted down by the formation of low melting point phase with the diffusion of Al and Si to the cast iron. Intermetallic compound layer consisted of Fe(Al,Si) 3 and Fe 2 Al 5 Si, the layer formed at cast iron side contained lower amount of Si.
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