Aluminium-iron Master Alloy，Aluminium iron Alloy，AlFe Alloy，E FORU

**Product Datasheet: Aluminium-Iron Master Alloy (Al-Fe Alloy)** **Version:** 1.0 | **Date:** 2025-04-02 --- ### **1. General Overview** Aluminium-Iron Master Alloy (Al-Fe Alloy) is one of the most fundamental and widely used master alloy systems in the aluminium industry. Iron serves as both a crucial alloying element for specific applications and a controlled impurity in others. This master alloy is essential for introducing iron into aluminium melts in a controlled manner, enabling the formation of intermetallic compounds that significantly influence mechanical properties, high-temperature performance, and electrical characteristics. --- ### **2. International Standards** Al-Fe master alloys are covered by numerous international standards: - **ISO:** ISO 209-1 (Wrought aluminium and aluminium alloys) - **ASTM:** ASTM B179 (Standard Specification for Aluminum Alloys in Ingot and Molten Forms) - **EN:** EN 1676 (Aluminium and aluminium alloys - Master alloys) - **AA:** Aluminum Association designations for 8xxx series alloys - **JIS:** JIS H 2118 (Aluminium alloy master alloys) - **Typical Master Alloy Grades:** Al-10%Fe, Al-20%Fe, Al-30%Fe, Al-40%Fe --- ### **3. Chemical Composition (Weight %)** Typical composition ranges for Al-Fe master alloy: | Element | Content (%) | Role & Remarks | |---------------------|-------------------|------------------------------------------| | Iron (Fe) | 5.0 – 40.0 | Primary alloying element | | Silicon (Si) | ≤ 0.25 | Impurity control | | Copper (Cu) | ≤ 0.05 | Impurity control | | Manganese (Mn) | 0 – 2.0 | Optional addition for phase modification | | Chromium (Cr) | 0 – 1.0 | Optional addition for enhanced properties | | Other Impurities | ≤ 0.15 total | — | | Aluminium (Al) | Balance | Base metal | --- ### **4. Physical Properties** | Property | Value / Range | |---------------------------|-----------------------------------| | Density | 3.0 – 4.0 g/cm³ | | Melting Range | 655 – 1150°C | | Intermetallic Phases | Al₃Fe, Al₆Fe, Al₅Fe₂, Al₁₃Fe₄ | | Thermal Conductivity | 90 – 160 W/m·K | | Electrical Conductivity | 35 – 50 % IACS | | Vickers Hardness | 60 – 120 HV | | Coefficient of Thermal Expansion | 19–23 × 10⁻⁶/K | --- ### **5. Key Characteristics & Advantages** - **Controlled Iron Addition:** Precise introduction of iron for specific alloy requirements - **Intermetallic Formation:** Creates hard phases for wear resistance - **High-Temperature Stability:** Maintains strength at elevated temperatures - **Electrical Applications:** Used in electrical conductor alloys - **Grain Refinement:** Modifies microstructure in casting applications - **Cost-Effective:** Economical alloying approach compared to pure iron additions --- ### **6. Product Applications** - **Electrical Conductors:** Overhead power transmission lines (Al-Fe alloys) - **Automotive Applications:** Cylinder liners, pistons, engine blocks - **Heat Exchangers:** Fins and tubes for elevated temperature service - **Wear-Resistant Parts:** Bearings, bushings, sliding components - **Packaging Materials:** Foil stock and can body stock - **Architectural Applications:** Cladding and roofing materials - **Additive Manufacturing:** Specialty powders for specific applications --- ### **7. Available Forms** - **Master Alloy:** Ingots, notch bars, waffle plates - **Special Forms:** Powder, granules, custom shapes - **Standard Sizes:** 5–20 kg ingots - **High-Purity Grades:** For electrical and electronic applications --- ### **8. Technical Guidelines for Use** - **Addition Rate:** 0.5–3.0% Fe to the melt (depending on target alloy) - **Melt Temperature:** 720–800°C - **Holding Time:** 30–60 minutes for complete dissolution - **Stirring:** Vigorous mechanical stirring required - **Cooling Rate:** Controlled solidification for desired microstructure - **Alloying Sequence:** Typically added after other alloying elements --- ### **9. Intermetallic Phase Formation** | Fe Content (%) | Primary Phases | Structure | Properties | |----------------|----------------|-----------|------------| | **<2.0** | Al₃Fe | Monoclinic | Moderate hardness | | **2.0–4.0** | Al₆Fe + Al₃Fe | Orthorhombic | High temperature stability | | **>4.0** | Al₅Fe₂ + Al₁₃Fe₄ | Complex | Excellent wear resistance | --- ### **10. Performance in Different Applications** | Application | Fe Content (%) | Key Benefit | Performance Characteristics | |-------------|----------------|-------------|----------------------------| | **Electrical Conductors** | 0.5–1.5 | Strength | 60–70% IACS, 150–200 MPa UTS | | **Engine Components** | 1.5–3.0 | Wear resistance | Hardness 80–100 HB, good thermal stability | | **Heat Exchangers** | 1.0–2.5 | Elevated temperature strength | Creep resistance to 300°C | | **Packaging Foil** | 1.0–2.0 | Strength | Good formability, uniform microstructure | --- ### **11. Quality Control Parameters** - Iron content consistency (±0.2%) - Intermetallic particle size distribution - Homogeneous microstructure - Low gas content (hydrogen < 0.15 ml/100g) - Controlled oxide inclusion levels --- ### **12. Health, Safety & Handling** - **Standard Handling:** Generally safe with standard precautions - **Dust Control:** Avoid inhalation of fine particles during processing - **Personal Protection:** Standard foundry PPE required - **Ventilation:** Adequate fume extraction recommended - **Storage:** Dry conditions to prevent excessive oxidation - **Disposal:** Follow standard metal disposal protocols --- ### **13. Economic & Supply Considerations** - **Cost-Effective:** Iron is abundant and inexpensive - **Supply Security:** Stable global supply chain - **Recycling:** Compatible with aluminium recycling streams - **Process Efficiency:** Higher recovery compared to pure iron additions --- ### **14. Specialized Grades** **Electrical Grade:** - Controlled impurity levels for maximum conductivity - Optimized intermetallic size and distribution - Enhanced mechanical properties **Wear-Resistant Grade:** - Higher iron content for increased hard phase volume - Modified with other elements for improved performance - Suitable for automotive and machinery applications --- ### **15. Research & Development Trends** - **Rapid Solidification:** Development of fine-grained microstructures - **Nanocomposites:** Al-Fe composites with enhanced properties - **Additive Manufacturing:** Optimized powders for 3D printing - **High-Temperature Alloys:** Advanced Al-Fe systems for elevated temperature service - **Recycling Optimization:** Improved processing of iron-containing scrap --- ### **Disclaimer** This information is provided for technical reference only. Properties and performance may vary based on specific application conditions, processing parameters, and cooling rates. While iron is generally considered an impurity in many aluminium alloys, its controlled addition through Al-Fe master alloy provides specific benefits in targeted applications. Users are advised to conduct thorough testing to determine suitability for their specific processes. Always follow good foundry practices and safety guidelines.

Packing of Standard Packing: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and steel drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 2297 gallon liquid totes Special package is available on request.