Microstructure at the diffusion bonding interface between Fe3Al and steel including Q235 low carbon steel and Cr18-Ni8 stainless steel was analysed and compared by means of scanning electron microscopy and transmission electron microscopy. The effect of Cr and Ni on microstructure at the Fe3Al/steel diffusion bonding interface was discussed. The experimental results indicate that it is favourable for the diffusion of Cr and Ni at the interface to accelerate combination of Fe3Al and steel during bonding. Therefore, the width of Fe3Al/Cr18-Ni8 interface transition zone is more than that of Fe3Al/Q235. And Fe3Al dislocation couples with different distances, even dislocation net occur at the Fe3Al/Cr18-Ni8 interface because of the dispersive distribution of Cr and Ni in Fe3Al phase.

The distribution of elements near the Fe3Al/Q235 diffusion bonding interface was computed by the diffusion equation as well as measured by means of EPMA. The results indicated close agreement between the two for iron and aluminium. Diffusion coefficient in the interface transition zone is larger than that in the Fe3Al and Q235 steel at the same temperature, which is favourable to elemental diffusion. The diffusion distance near the Fe3Al/Q235 interface increased with increasing heating temperature, T, and the holding time, t. The relation between the width of the interface transition zone, x, and the holding time, t, conformed to parabolic growth law: x2=4

The microstructure near a diffusion interface was studied by means of scanning electron microscopy and electron probe microscopy, and the results indicated that the interface transition zone of Fe3Al/Q235 dissimilar materials was composed of a diffusion interface, a mixed transition region, and A/B transition regions at the sides of the interface. Microstructures of the interface and base materials were interlaced to form the microstructure of layer characteristic. With increased heating temperature and holding time, the width of the Fe3Al/Q235 interface transition zone increased and the microstructure gradually became coarse. The microhardness in the diffusion transition zone was decreased and there was a peak value at the diffusion interface. The distribution of Al, Fe, and Cr in the interface transition zone was increased or decreased monotonically with some local concentration fluctuation. There was nearly no change in the concentration of C element near the interface.