Secondary phases in the microstructure of cast alloys can greatly increase the complexity of functional film development, particularly when film growth is induced by diffusion. This paper examines the effect of secondary phases on the diffusion behaviors of aluminum, oxygen, and nitrogen, each of which plays an important role in the formation of functional films on cast aluminum and gray cast iron alloys. In general, a fine and evenly distributed phase morphology improves the uniformity of functional films regardless of whether the secondary phase accelerates or delays mass transfer during diffusion.

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