Effect of Mold Casting Parameters in Interface Properties of Iron/Copper Bimetallic Composites Based upon an Ancient Quranic Metal Matrix Composite (QMMC)

Abstract

The relation between iron/copper bimetallic composites has many challenges; one of the most important characteristics is their diffusion and its effect on the properties of the interface region. This paper studies the influence of casting parameters on the interface region of these bimetallic composites and compares it to observations on those of the Quranic metal matrix composites based on the Dhul-Qarnayn dam (Gog and Magog Wall). A different number of steel rods (one, two, and three) were placed in an alloy steel mold, then heated at different temperatures of 350, 450, 550, and 650 °C. After that, molten copper was poured over them into the mold, followed by different cooling rates (fast, medium, and slow). The properties of the interface region (microstructure, microhardness, and bonding strength) were investigated. The finite element model was carried out to obtain the temperature distribution through the specimen. The microhardness test results revealed that the high preheating temperature and high cooling rate give a high interface microhardness due to the formation of iron oxides and fine grains. The present experimental results show the highest bond strength between steel and copper, which was achieved when the temperature of the interface region reached the austenitic phase (γ-phase) and held it sufficiently to reach a successful substitutional diffusion mechanism. The bond strength between copper and steel in each casting parameter obtained experimentally was used to predict the tensile strength of the obtained bimetal composites numerically.