Abstract

In this work, we investigate Cu solution in θ-Al13Fe4 and related Al-rich ω-Al7Cu2Fe and Al2Cu phases in the Al-Cu-Fe system using the first-principles density functional theory (DFT) with on-site Coulomb interaction correction. The results show preference of Cu at Al7, forming a ternary θ-Al76Cu2Fe24 at ambient conditions, and both Al7 and Al9 sites (in Grin’s note), forming θ-(Al76−xCu2+x)Fe24 at a high temperature. The relative stability of the Al-rich compounds and their crystal and electronic properties are investigated. We show the importance of the Hubbard U correction to the standard DFT functionals for Cu-containing metallic materials. This study helps characterize the intermetallic compounds in Cu-containing Al alloys, and helps further control Fe-containing intermetallic compounds in the solidification of Al-based alloys.

Highlights

  • Fe is the most common impurity in commercial Al metals [1,2]

  • Due to its low solubility in Al, Fe exists in the form of Fe-containing intermetallic compounds (Fe-IMCs), including the primary θ-Al13 Fe4

  • The recycling economy requires that harmful Fe-IMCs, including θ-Al13 Fe4, be minimized or at least controlled in the products during the casting of Al alloys, especially Al scrap, which contains various impurities, including Fe [8,9,10]

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Summary

Introduction

Due to its low solubility in Al, Fe exists in the form of Fe-containing intermetallic compounds (Fe-IMCs), including the primary θ-Al13 Fe4. These Fe-IMCs deteriorate the mechanical performance of cast. Al-Cu alloys, including the 2000- and 800-series, have attractive advantages: being light-weight, high strength, and age-hardening. They have been widely utilized in aerospace and automobile industries [1,5,6,7]. The recycling economy requires that harmful Fe-IMCs, including θ-Al13 Fe4 , be minimized or at least controlled in the products during the casting of Al alloys, especially Al scrap, which contains various impurities, including Fe [8,9,10]

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