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<p>To address the issues of excessive intermetallic compound growth and weak interfacial bonding strength in Al–Sn/steel composites, Al–Sn/steel and Al–Sn/Al bronze/steel layered materials were prepared by arc deposition technology. The influence of an Al bronze interlayer on the microstructure, mechanical properties, and tribological behavior of layered composites was systematically investigated. The results demonstrate that the introduction of an Al bronze interlayer optimized the interfacial structure and phase composition of Al–Sn layer. At the interface, Al–Al<sub>2</sub>Cu eutectic layer and Al<sub>2</sub>Cu intermetallic compound (IMC) layer formed, replacing the brittle Fe–Al IMC layer. Al–Sn layer remained primarily composed of α-Al solid solution, free β-Sn phase, and Al–Al<sub>2</sub>Cu eutectic structures. However, the eutectic content increased to 14.53% and interconnected into a network, strengthening the cohesion between phases. Mechanical testing revealed that the micro-hardness of Al–Sn layer improved from 46.43 to 74.15 HV, the bonding strength between Al–Sn layer and the substrate increased from 31.3 to 92.9 MPa, and the tensile strength and elongation of Al–Sn coating increased by 47.19% and 53.54% respectively. Tribological evaluations indicated that Al bronze interlayer reduced the dry friction coefficient from 0.54 to 0.31 and decreased wear volume by 94%.</p>

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Effect of Al bronze interlayer on mechanical properties and tribological behavior of Al–Sn/steel composite materials prepared by wire-arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Zan Wang,
  • Liang Wang,
  • Shuo Wang,
  • Meng-Meng Yang,
  • Jian Zhou,
  • Feng Xue

摘要

To address the issues of excessive intermetallic compound growth and weak interfacial bonding strength in Al–Sn/steel composites, Al–Sn/steel and Al–Sn/Al bronze/steel layered materials were prepared by arc deposition technology. The influence of an Al bronze interlayer on the microstructure, mechanical properties, and tribological behavior of layered composites was systematically investigated. The results demonstrate that the introduction of an Al bronze interlayer optimized the interfacial structure and phase composition of Al–Sn layer. At the interface, Al–Al2Cu eutectic layer and Al2Cu intermetallic compound (IMC) layer formed, replacing the brittle Fe–Al IMC layer. Al–Sn layer remained primarily composed of α-Al solid solution, free β-Sn phase, and Al–Al2Cu eutectic structures. However, the eutectic content increased to 14.53% and interconnected into a network, strengthening the cohesion between phases. Mechanical testing revealed that the micro-hardness of Al–Sn layer improved from 46.43 to 74.15 HV, the bonding strength between Al–Sn layer and the substrate increased from 31.3 to 92.9 MPa, and the tensile strength and elongation of Al–Sn coating increased by 47.19% and 53.54% respectively. Tribological evaluations indicated that Al bronze interlayer reduced the dry friction coefficient from 0.54 to 0.31 and decreased wear volume by 94%.