1. Investigation of Aluminum/Brass interface
Department of metallurgy and Materials Engineering
Morteza Gholami
Supervisors :
Dr. Divandari , Dr. Salehi
November 2014

2. CONTENT 01 02 03 04 05 Bimetal importance The Role of interface
analysis of Aluminum/Brass interface in various processes 04
Compound casting 05
conclusion

3. 1 Bimetal importance Requirements incorporation Weigh reduction
The importance of reducing consumption
Improving production efficiency 1
Bimetal importance

4. 2
The role of interface

5. 1 3 5 2 4 FIVE PROCESS Accumulative Roll bonding Cold rolling
It is a method of producing roll –clad plates or sheets by hot rolling a welded composite of steel clad plate and a plate of a more corrosion material, such as stainless steel.
The rolling of steel or other metal at room temperature to preserve it’s original crystal structure.
Ultrasonic
consolidation
Friction stir
welding
It is a method of rolling a stack of metal sheets , which is repeatedly rolled to a sever reduction ratio, sectioned into two halves, piled again and rolled.
An additive manufacturing technique based on the ultrasonic welding of metal foils.
It is a solid-state joining process (the metal is not melted) that uses a third body tool to join two facing surfaces.
FIVE
PROCESS

6. Cold rolling {1977} 4 Critical thickness : generally > 1mm
Annealed at a) 500 ͦ, 0.5h b) 540 ͦ, 0.5h c) 540 ͦ, 2h
α (solid solution) 2) ɤ2 (Cu9Al4) 3) δ (Cu3Al2)
At temperatures above 520 ͦ : θ (CuAl2)
Critical thickness : generally > 1mm

7. 5
Cold rolling {1977}

8. Glow phenomenon {1980} 6
Reaction production : CuAl2, Cu4Al3, CuAl, Cu3Al2 respectively

9. Glow phenomenon {1980} 7
Reaction production : CuAl2, Aluminum solid solution

10. 8
Glow phenomenon {1980}
Reaction production : Cu9Al4

11. 9
Roll-bonding { }
Interdiffusion layer after : a) 250 ͦ, 765h b) 400 ͦ, 6h

12. 10 Roll-bonding {1985-1988} Intermetallic growth at 55 ͦ
Critical thickness : 2µm 10
Roll-bonding { }

13. 11
UC {2007}
Indirect welding
Direct welding

14. 12
Annealed brass layer
ARB { }

15. ARB { } 13
Fracture surfaces

16. 14 FSW {2011-2013} Transient layer (point 3) : Cu9Al4
Dark gray layer (point 1) : CuAl2
Light gray layer (point 2) : CuZn

17. FSW { } 15

18. Compound Casting wettability Heat transfer Surface tension Surface16
Casting
Compound casting is an economic process which enables forming the shape of the product and bonding other parts with complex structures to castings at the same time.
wettability
The ability of solid surface to reduce the surface tension of a liquid in contact with it such that it spreads over the surface and wets it.
Heat
transfer
Metals with lower surface tensions and contact angles provided better heat transfer.
With increasing surface roughness, the maximum interfacial heat transfer increases at first an after reaching a maximum value , starts to decrease.
Surface
tension
Surface
roughness
A contractive tendency of the surface of a liquid that allows it to resist an external force.

19. Compound casting 17

20. Compound casting {2013} 18 L / S = 3 , Tpouring = 700

21. CuZn 2) Al4Cu3Zn 3) Al2Cu
Compound Casting {2013} 19

22. Compound Casting {2013} 20

23. FSW Compound Casting Roll bonding Conclusion21
Conclusion
FSW
Compound Casting
Roll bonding
Reaction layer consist of three intermetallic layers, a eutectic layer and a dendritic layer with eutectic phase between dendrite arms in vicinity of Aluminum. EDS result shown that intermetallic layers composed of CuZn, Al4Cu3Zn and Al2Cu .
Reactional diffusion layer is consisting of :
α-solid solution of aluminum in copper,
ɤ2 phase (Cu9Al4), δ phase (Cu3Al2)
θ-phase appearing only at higher temperatures.
All phases are rich in Zinc .
At rotation speeds higher than 450rpm a multilayer intermetallic compound form at interface. This layer is mainly composed of CuZn, CuAl2, and Cu9Al4 .

24. references 22
[1] MOSTAFA AKBARI and REZA ABDI BEHNAGH “Dissimilar Friction-Stir Lap Joining of 5083 Aluminum Alloy to CuZn34 Brass” The Minerals, Metals & Materials Society and ASM International 2012
[2] Yasser Fouad “Characterization of High Strenght Stainless Steel/Al/Brass Composite Tri-layered Clad” Trans Indian Inst Met, 2014
[3] مهدی اکبری فر، مهدی دیواندری «بررسی فصل مشترک آلومینیوم/برنج به روش ریخته گری مرکب» دومین همایش بین المللی و هفتمین همایش مشترک انجمن مهندسی متالورژی ایران و انجمن ریخته گری ایران، 1392
[4] G.D. Janaki Ram, C. Robinson, Y. Yang and B.E. Stucker “Use of ultrasonic consolidation for fabrication of multi-material structures” Rapid Prototyping Journal (2007), Volume 13, Issue 4,
[5] R.S. Timsit “INTERMETALLICS GROWTH AT AL/α-BRASS INTERFACES” Acta Metallurgica, Volume 33, Issue 1, January 1985, Pages
[6] D. Bouchard, S. Leboeuf, J.P. Nadeau, R.I.L. Guthrie, M. Isac “Dynamic wetting and heat transfer at the initiation of aluminum solidification on copper substrates” J. Mater. Sci. 44 (2009)

25. Thanks to all “
Good luck