The morphology of coating/substrate interface in hot-dip-aluminized steels

In hot-dip-aluminized (HAD) steels, the morphology and the profile of the interface between the aluminum coating and the substrate steel, are affected both by the composition of the molten aluminum as well as by the composition, and even the microstructure, of the substrate steel. This effect has been investigated using optical and scanning electron microscopy, and X-ray diffraction. The reaction between the steel and the molten aluminum leads to the formation of Fe–Al inter-metallic compounds on the steel surface. The thickness of the inter-metallic compound layer as well as the morphology of the interface between the steel and the interlayer varies with the silicon content of the molten aluminum. In hot-dip-aluminizing with pure aluminum, the interlayer is ‘thick’ and exhibits a finger-like growth into the steel. With a gradually increasing addition of silicon into the aluminum melt, the thickness of the interlayer decreases while the interface between the interlayer and the substrate gradually becomes ‘smoother’. With an increase in the carbon content of the substrate steel the growth of the interlayer into the steel is impeded by the pearlite phase, whereas the ferrite phase appears to dissolve more readily. X-ray diffraction and electron microscopic studies showed that the interlayer formed in samples aluminized in pure aluminum, essentially consisted of orthorhombic Fe2Al5. It was further observed that the finger-like grains of Fe2Al5 phase exhibited a preferred lattice orientation. With a gradual addition of silicon into the aluminum melt, a cubic phase based on Fe3Al also started to form in the interlayer and replaced most of the Fe2Al5.