Abstract
A method was investigated to minimise or totally prevent the formation of the undesirable Al4C3 phase in high-aluminium cast iron composites (>19% Al). When aluminium carbide is absent in these castings, both mechanical strength and corrosion resistance are significantly improved. Accordingly, Ti additions were introduced to high-aluminium cast iron to develop Fe-Al-Ti-C alloys, which resemble “in-situ” composites where the inter-metallic FeAl phase is the matrix, and TiC acts as the reinforcement. It was found that the minimal amount of Ti that needs to be added has to be equal or above 4.5 wt% in order to totally remove the Al4C3 phase. It was found that Fe-Al-Ti-C alloys exhibit relatively high oxidation resistance, which easily exceeds that of high-chromium cast iron and cast chromium steels. Finally, in order to improve alloy ductility, minor alloy additions of elements such as B and Cr were added to the melt. It was found that additions of 0.03% B and 0.03%B-5% Cr combined with heat treatment lead to significant improvements in the ductility of the alloy with elongations of up to 15%.
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