Compound Casting of Aluminum with Sheet Steel in 3D Sand Casting Using an Inductive Heating System

Compound casting is a process in which a single component is made from two metallic materials, such as aluminum and steel. Solid-liquid bimetallic compounds can be produced by suitable process control. This technology can reduce the number of joining processes, and the specific properties of the res...

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Bibliographic Details
Published in:Metals (Basel ) 2023-02, Vol.13 (2), p.354
Main Authors: Locke, Christopher, Guggemos, Martin, Gruber, Maximilian, Maier, Lorenz, Mayr, Lukas, Weiß, Tony, Volk, Wolfram, Günther, Daniel
Format: Article
Language:English
Subjects:
3D sand casting
Aluminum
aluminum/steel
Bimetals
Bonded joints
Casting
compound casting
Crack initiation
Heating
induction
Intermetallic compounds
Intermetallic phases
Investigations
Iron and steel making
joining
Laser ablation
Lasers
Mechanical properties
Metal sheets
Nickel
Photomicrographs
Sand casting
Shear tests
Sheet-steel
Steel pipes
Strip steel
Temperature
Tensile strength
Tensile tests
Zinc
Zinc coatings
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Summary:Compound casting is a process in which a single component is made from two metallic materials, such as aluminum and steel. Solid-liquid bimetallic compounds can be produced by suitable process control. This technology can reduce the number of joining processes, and the specific properties of the respective metal component can be used for specifically designed product properties, for example, where lightweight and high strength are needed. This paper presents an experimental methodology for producing a purely material-bonded bimetallic joint from cast aluminum and zinc-coated sheet steel in 3D sand casting using an inductive heating system. The process-related temperature characterisation in the compound zone is described using a heating test rig and temperature measurements. It shows that inductive preheating can only produce a material bond between the aluminum casting and the coated steel sheet. Shear tensile tests showed strengths between 15 MPa and 22 MPa. Laser surface pre-treatment using laser ablation cutting on the coated steel sheet was carried out to investigate the benefit of possible microform-locking. The results show a strength-reducing influence on the tensile shear tests. Micrographs showed the formation of Al4.5FeSi and Al7Fe2Si, as well as the formation of other undefined intermetallic phases. The thickness of the compound zone is 10 µm.
ISSN:2075-4701
2075-4701
DOI:10.3390/met13020354