Formation of Die Soldering and the Influence of Alloying Elements on the Intermetallic Interface

• Published in: Materials 2021-03, Vol.14 (7), p.1580
• Main Authors: Kohlhepp, Marius, Uggowitzer, Peter J, Hummel, Marc, Höppel, Heinz Werner
• Format: Article
• Language: English
• Subjects: Alloying elements; Aluminum alloys; Aluminum base alloys; Beta phase; Chemical elements; Chromium; Die casting; Die castings; Dies; Ductility tests; Experiments; Interfaces; Intermetallic phases; Manganese; Molybdenum; Morphology; Soldering; Spectrum analysis; Thickness; Tool steels
• ISSN: 1996-1944; 1996-1944
• DOI: 10.3390/ma14071580

Die soldering of die castings is a serious problem in the aluminum casting industry. The precise mechanism, the influence of the alloy composition, and the options for prevention have not yet been fully elaborated. A well-established solution for alloys with low iron content is the addition of manganese. However, up to 0.8 wt.% is necessary, which increases the amount of brittle phases in the material and consequently reduces ductility. Immersion tests with 1.2343 tool steel and pure aluminum as well as a hypoeutectic AlSi-alloy with Mn, Mo, Co, and Cr additions were carried out to systematically investigate the formation of die soldering. Three different intermetallic layers and a scattered granular intermetallic phase formed at the interface between steel and Al-alloy after immersion into the melt for a duration of 6 min at 710 °C. The combined presence of the irregular, needle-shaped β-Al FeSi phase and the surrounding alloy was responsible for the bond between the two components. Mn and Mo inhibited the formation of the β-phase, and instead promoted the α -Al (Fe,X) Si phase. This led to an evenly running boundary to the AlSi-alloy and thus prevented bonding. Cr has proven to be the most efficient addition against die soldering, with 0.2 wt.% being sufficient. Contrary to the other elements investigated, Cr also reduced the thickness of the intermetallic interface.