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Hot dip aluminizing of mild steel at different temperatures was conducted to reveal the influence of reaction temperature and time on interfacial intermetallic compounds (IMCs). Scanning electron microscopy, energy dispersive X-ray spectrometry and X-ray diffraction were employed to investigate the interfacial microstructures. The IMCs of the dipping interface consisted of a thick layer of η-Fe 2 Al 5  between 4.2–132.2 μm next to the steel and a thin layer of θ-Fe 4 Al 13  between 0–5.5 μm close to the aluminum. With increasing dipping temperature and time, the total thickness of IMCs (Fe 2 Al 5  plus Fe 4 Al 13 ) increased. Specifically, the growth of the Fe 2 Al 5  layer can be described by parabolic rate laws. An activation energy of 93 kJ mol −1  was obtained, combining both the results from the present work and previous studies in the temperature range of 675–900°C. The change in Fe 4 Al 13  thickness is not significant compared with the Fe 2 Al 5 . However, the decrease in IMC thickness of the Fe 4 Al 13  with dipping temperature was observed for the first time and had never been reported before. Moreover, it can be clearly observed that the thickness of the Fe 4 Al 13  decreased with dipping time based on the linear fitting results by excluding the result of the initial 1 s. A possible mechanism is that interfacial dynamics and thermodynamics work for the dissolution and decomposition of the Fe 4 Al 13  layer. Higher temperature accelerates the dissolution of the θ layer.

Kinetics of intermetallic compound layers during initial period of reaction between mild steel and molten aluminum