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Achieving Metallurgical Bonding in Aluminum/Steel Bimetallic Castings

Journal Article · · International Journal of Metalcasting
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Abstract

Aluminum castings are increasingly being used in automotive powertrain and structural applications for vehicle lightweighting. Cast aluminum parts often need to be machined and joined to steel components in multi-material systems. Bimetallic components produced by casting aluminum over steel substrate are advantageous due to the elimination of machining and traditional dissimilar material joining processes. However, forming a strong metallurgical bonding during overcasting process has been challenging. In this paper, the effects of processing conditions such as substrate surface preparation, pre-heating temperature, melt conditions as well as casting design were studied by investigating the bimetallic interfaces for aluminum A319 casting alloy and a high alloy steel substrate in a sand-casting process. Zn and Al-based substrate coatings were evaluated. The experimental results suggest a metallurgical bond between aluminum and steel can be formed during the sand-casting process via high temperature diffusion with or without coatings. Al-based substrate coating prior to overcasting results in the formation of a continuous layer of intermetallics at the bimetallic interface, with large Al–Si–Fe intermetallics penetrating the cast aluminum.

Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
Grant/Contract Number:
EE0008877
OSTI ID:
2281636
Journal Information:
International Journal of Metalcasting, Journal Name: International Journal of Metalcasting Journal Issue: 4 Vol. 18; ISSN 1939-5981
Publisher:
Springer Science + Business MediaCopyright Statement
Country of Publication:
Switzerland
Language:
English

References (10)

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Composite Casting and Characterization of Cu–Al Bilayer Compounds journal May 2019
Influences of Coating Type on Microstructure and Strength of Aluminum–Steel Bimetal Composite Interface journal June 2021
Novel Approach for Using Ductile Iron as Substrate in Bimetallic Materials for Higher Interfacial Bonding Bearings journal August 2021
Effect of Mn Addition to Al–Si Alloy on the Layer Formed at the Interface with Cast Iron in Compound Casting journal March 2023
Interface chemistry in aluminium alloy castings reinforced with iron base inserts journal October 2002
Mechanical testing of steel/aluminium–silicon interfaces by pushout journal July 2007
Effects of hot-dip galvanizing and aluminizing on interfacial microstructures and mechanical properties of aluminum/iron bimetallic composites journal December 2016
Iron-Containing Intermetallic Phases in Al-Si Based Casting Alloys journal January 2012
Making sustainable aluminum by recycling scrap: The science of “dirty” alloys journal July 2022

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