Characterization and Microhardness Evaluation of A356/Mg Joint Produced by Vacuum-Assisted Sand Mold Compound Casting Process

Tayal, Rajender Kumar; Kumar, Sudhir; Singh, Vikram; Garg, Rohit

doi:10.1007/s40962-018-0264-x

Cited by 11 publications

(4 citation statements)

References 39 publications

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“…In order to avoid/reduce the brittle intermetallics formed at the dissimilar material interface during welding processes, Tayal et al [166,167] studied the joining of A356 Al casting and Mg through compound casting, where molten Mg was poured into the mould with the A356 insert and joined together. The process parameters of compound casting, including pouring temperature, vacuum pressure, insert temperature, and surface roughness of insert could be optimized according to the hardness profile along the joint interface.…”

Section: Other Joining Methodsmentioning

confidence: 99%

Joining Technologies for Aluminium Castings—A Review

Slater

Cai

et al. 2023

Coatings

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Aluminium castings have been widely used in many industries, including automotive, aerospace, telecommunication, construction, consumer products, etc., due to their lightweight, good electric and thermal conductivity, and electromagnetic interference/radio frequency interference (EMI/RFI) shielding properties. The main applications of aluminium castings are in automotive industry. For lighweighting purposes, more and more aluminium castings are used in the automotive vehicle structures to reduce weight, improve fuel efficiency, and reduce greenhouse gas emissions. However, due to the features of cast aluminium, such as porosity, poor surface quality, a tendency toward hot cracking, and low ductility, joining these materials is problematic. In this paper, the joining technologies for aluminium castings and the related issues, mainly cracking and porosity, are reviewed. The current state-of-the-art of joining technologies is summarized, and areas for future research are recommended.

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Section: Other Joining Methodsmentioning

confidence: 99%

Joining Technologies for Aluminium Castings—A Review

Slater

Cai

et al. 2023

Coatings

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“…The bimetallic casting process is a technology in which two metals form a permanent intermetallic bond. Thanks to relatively low production costs, this method has found wide application in the production of bimetallic materials [3][4][5][6], consisting of material pairs such as aluminium and copper, aluminium and magnesium and aluminium and cast iron [7][8][9][10]. With the current development of the efficiency of high-power internal combustion engines, the pistons produced and used in them have reinforcements in the form of cast iron inserts.…”

Section: Introductionmentioning

confidence: 99%

“…Although many methods have been developed to join aluminium with aluminium and aluminium with Fe-based alloys, such as rolling [33], riveting [34], conventional laser welding [35,36], high-speed fibre laser welding [37], oscillating laser welding [38] and friction stir welding [39,40] it is hard to claim that these methods are easy to implement when joining elements with complex-shaped components [41]. The casting process, by means of which liquid metals can be joined with solid metals in the metallurgical process, has great flexibility when joining elements with complex shapes [42]. For example, Liu et al [43] developed a new method of casting composites involving hot dipping in a Zn-7Si 2.2 wt.% alloy for metallurgical bonding of aluminium alloys to mild steels.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Duration and Temperature of the Al-Fin Process for the Cast Iron Insert on the Microstructure of the Bimetallic Joint Obtained in the Piston Casting Process

Szwajka

Zielińska-Szwajka

Trzepieciński

2023

Metals

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The aim of this work was to determine the effect of the duration and temperature of the Al-Fin process for casting the bimetallic joint on the formation of the metallurgical bond between the AlSi9 aluminium alloy piston and the cast iron insert. Knowledge about the formation of individual bonding layers has a direct impact on the bonding strength between the aluminium alloy and the EN-GJLA-XNiCuCr15-6-2 austenitic cast iron ring. In the performed tests, the Al-Fin casting process was carried out for different temperatures of the liquid AlSi9 alloy. The temperature of the AlSi9 aluminium alloy varied in the range 700–950 °C in steps of 50 °C. The duration of the Al-Fin process ranged from 1 to 10 min. An optical microscope and a scanning electron microscope were used to study the microstructure of the bimetallic joints. The analysis of the microstructure of the bimetallic bond showed that characteristic layers are formed between the aluminium alloy piston and the cast iron insert: a transition layer, in which iron and aluminium atoms from both joined materials are mixed, and a diffusion layer, in which aluminium and silicon atoms penetrate the surface layer of the joined metals. The thickness of the intermetallic diffusion layer formed between the aluminium alloy and the cast iron insert is thinner and does not depend on the heating time of the aluminium insert in the bath. However, there is a significant effect of both the annealing time and the temperature of the AlSi9 aluminium alloy on the thickness of the transition zone.

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“…3 Another research used aluminum alloy as an insert material and magnesium as another metal melted. 4,5 Bakke et al experimented on the bimetal joint of aluminum alloy and copper. A flux coating was applied to the insert material (copper pipes) to reduce the oxide layer between aluminum alloy and copper pipes.…”

Section: Introductionmentioning

confidence: 99%

Improving Bimetal Bond Quality Between Cast Steel and Aluminum Alloys Using Response Surface Methodology

Suryadarma

Bawono

et al. 2021

Inter Metalcast

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Currently there is greater interest and an industrial need to create a bond between cast steel and aluminum alloys. The bond quality between these two metals must be considered, since it is affected by several casting techniques and parameters. This research aims to find the right combination of techniques and parameters to make a good bond between cast steel and aluminum alloys. This research systematically used the response surface methodology (RSM). Three important casting techniques and parameters are selected as independent variables, which are preheating temperature of cast steel, pouring temperature of aluminum alloy molten, and surface cleaning of cast steel. The gap between cast steel and aluminum alloy is used as dependent variable, which is defined as the quality measurement of the bond between two metals. The experiments were conducted on 48 samples, in which destructive test was performed in order to measure the gap. From the methodology, it is found that the recommended preheating temperature of cast steel is 491 °C, the recommended pouring temperature of aluminum alloy is 696 °C, and the recommended technique is cleaning the cast steel insert using degreasing. For practical purpose, the preheating temperature of cast steel can be set at 490 ± 10 °C and the pouring temperature of aluminum alloy can be set at 695 ± 10°C. This research limits on bimetal casting between cast steel and aluminum alloys, and the casting process is gravity die casting process. This paper is able to find the best casting techniques and parameters for cast steel and aluminum alloy bond using RSM. This paper also proposes gap bond between two metals as bond quality measurement.

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Characterization and Microhardness Evaluation of A356/Mg Joint Produced by Vacuum-Assisted Sand Mold Compound Casting Process

Cited by 11 publications

References 39 publications

Joining Technologies for Aluminium Castings—A Review

Joining Technologies for Aluminium Castings—A Review

Influence of the Duration and Temperature of the Al-Fin Process for the Cast Iron Insert on the Microstructure of the Bimetallic Joint Obtained in the Piston Casting Process

Improving Bimetal Bond Quality Between Cast Steel and Aluminum Alloys Using Response Surface Methodology

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