The infiltration of aluminum melts into porous metal skeletons produced by powder metallurgy methods, including 3D printing, under a pressure gradient was studied. The densification of compacts made of iron powder with various blowing additions was examined. The minimum pressures at which 35–40% porosity was reached were found to be 150–200 MPa. The use of metal iron shavings allowed a porous skeleton to be formed at a lower pressure (100 MPa). The minimum pore size (400 μm) ensuring complete filling of the porous skeleton with an aluminum melt heated to 760–780°C under a pressure gradient was established. The potential production of iron–aluminum composites without the formation of chemical compounds was shown. A thin discrete layer 5–10 μm thick was observed at the interface between iron and aluminum, where the iron skeleton became saturated with aluminum. This layer provides better adhesion between the iron skeleton and the aluminum melt. The absence of chemical compounds in the Fe–Al system in impregnation conditions is explained by the process kinetics: the components cannot react with each other within several seconds. The effect exerted by the type of porous skeletal structure on the compressive strain of the iron–aluminum composites was established. The greatest compression strength (~400 MPa) was shown by the samples produced from 3D skeletons. The stress–strain curves for the samples with 3D skeletons show two bends: one is in the range 60–70 MPa (beginning of plastic deformation) where strain hardening occurs and strain increases to 20–22% and the other begins at 230–240 MPa and determines the bulk deformation of the samples. The highest yield stress was observed for the samples with shavings-based skeletons (115.2 MPa), which is associated with a high contact surface area of the shaving particles that are randomly intertwined. Accordingly, the lowest characteristics were shown by the samples with skeletons consisting of powder particles with the minimum contact area.

中文翻译：

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多孔骨架铁结构对铝熔体渗透的影响

研究了铝熔体在压力梯度下渗透到通过粉末冶金方法（包括 3D 打印）生产的多孔金属骨架中。检查了由具有各种发泡添加剂的铁粉制成的压块的致密性。发现孔隙率达到 35-40% 时的最小压力为 150-200 兆帕。使用金属铁屑可以在较低压力 (100 MPa) 下形成多孔骨架。确定最小孔径 (400 μm)，以确保在压力梯度下将铝熔体加热至 760-780°C 完全填充多孔骨架。显示了在不形成化合物的情况下生产铁铝复合材料的潜力。在铁和铝的界面处观察到 5-10 μm 厚的离散薄层，铁骨架被铝浸透的地方。该层在铁骨架和铝熔体之间提供更好的附着力。在浸渍条件下，Fe-Al 系统中不存在化合物是由工艺动力学解释的：组分不能在几秒钟内相互反应。确定了多孔骨架结构类型对铁铝复合材料压缩应变的影响。由 3D 骨架制成的样品显示出最大的压缩强度 (~400 MPa)。具有 3D 骨架的样品的应力-应变曲线显示出两个弯曲：一个在 60-70 MPa（塑性变形的开始）范围内发生应变硬化并且应变增加到 20-22%，另一个在 230-240 MPa 处开始MPa 并确定样品的整体变形。对于具有基于刨花的骨架 (115.2 MPa) 的样品，观察到最高屈服应力，这与随机缠绕的刨花颗粒的高接触表面积有关。因此，具有由具有最小接触面积的粉末颗粒组成的骨架的样品显示出最低的特性。