Characterization of intermetallic compound layer thickness at aluminum–steel interface during overlaying

• We record welding pool temperature using Infrared thermography system during Fe–Al overlaying.
• We calculate Fe2Al5 layer thickness according to thermodynamics formula and temperature data.
• We measure Fe2Al5 layer thicknesses in SEM images.
• The calculated results are in agreement with measured results.

In this research, the thicknesses of Fe2Al5 sub-layer (lFe2Al5) in bead welds were roughly calculated according to the formula l = Kt1/2. The values of constant K and residence time t were obtained through recording welding pools temperature. Fe2Al5 sub-layers were also observed and their thicknesses were measured by SEM and EDS analysis. The calculated results were in close agreement with measured results, demonstrating the accuracy of these calculated Fe2Al5 sub-layer thicknesses.

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