Simulation study of block press molding of Al-Fe metals with different morphologies

In this paper, the Al-Fe composite metal containing 40% of Al is taken as the research object, and the granular 40Al-Fe composite metal and chip Al-Fe composite metal are pressed and predeformed respectively, focusing on the second hot compression deformation of the chip Al-Fe composite metal preformed billet, to study the effect of pressing predeformation and hot compression on the formability and interface of Al-Fe composite metal. The results show that the granular 40Al-Fe composite metal preforms (density of 4.54 g/cm³) at a pressure of 16 MPa have good formability and form a dense interface. Pressure of 16 MPa when the chip-like 40Al-Fe composite metal prefabricated billet (density of 3.50 g/cm³) can be molded but there are holes in the interface, Al chips are mainly “lamellar”, “dogtooth”, “circle”, “wave”, after the second hot compression deformation “circle” Al chips into a whole, “dogtooth” and “wavy”, “dogtooth” and “wavy”. “Circle-like”, “wave-like”, after the second thermal compression deformation “circle-like” Al shavings connected to a whole, “dogtooth-like” and “wave-like” Al shavings, “dogtooth-like” and “wave-like” Al shavings, “dogtooth-like” and “wave-like” Al shavings. “Wave-like” Al chips are evolved into “lamellar”, after the second thermal compression deformation Fe chips are still “lamellar”, “blocky”, without obvious deformation occurs. The deformation temperature of 300 ℃, deformation rate of 0.5 s⁻¹, and the degree of deformation of 0.1 are the best parameters of the current production process, at which time the shavings of 40Al-Fe composite metal have the best formability and good interfacial bonding (density of 4.66 g/cm³).