Study of Intermetallic Components in Al Wire Interface Inserted in Gray Cast Iron Microstructure Produced Via Lost Foam Casting

Lost foam casting has been used as a production method since 1950. This process has the capability to put different types of fiber and particles inside the polystyrene pattern before starting to cast. The process utilized in this research can be also regarded as a promising approach for production composite and bimetals. Furthermore, this process can be used for studying interface reactions between a given melt and supposed solid insert. In this research, Aluminum wire with a diameter of 3 mm inserted in polystyrene pattern and then gray cast iron was poured. States of melting Aluminum insert, different Fe/Al intermetallic phases and effect of Aluminum on the graphite in interface were studied by Scanning Electron Microscopy. Results showed that formation of different intermetallic components such as FeAl3, FeAl2, FeAl and Fe3AlCx at Fe/Al /C interface.