Abstract
The use of inserts allows for the selective reinforcement of castings to improve mechanical properties, including surface hardness and wear rate. Metal surfaces that undergo wear on account of friction can be strengthened using metal matrix composite (MMC) inserts. An essential factor in the manufacture and application of compound casting involving MMC inserts has been the bond strength between the insert and alloy. This work studied fluxes (CsAlF4 and LiAlF4), preheating, and nickel (Ni) plating to improve the bond strength between A206 and A201-Al2SiO5 fiber MMC. It was observed that Flux 1 (G-2004), Flux 2 (CS-2020), and Ni plating, when used with preheating the insert up to 200 °C, led to the formation of a diffusion bond. The effect of fluxes and plating has been discussed, along with the impact of the insert oxide layer on the formation of diffusion bonds. The microstructure formed at the interface between casting and insert was analyzed.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig3_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig4_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig5_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig6_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig7_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig8_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig9_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig10_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig11_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig12_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40962-024-01270-3/MediaObjects/40962_2024_1270_Fig13_HTML.jpg)
Similar content being viewed by others
References
Green, J.A.S. Ed. Aluminum recycling and processing for energy conservation and sustainability ASM International (2007)
R.S. Rana, R. Purohit, S. Das, Reviews on the influences of alloying elements on the microstructure and mechanical properties of aluminum alloys and aluminum alloy composites. Int J Scient Res Publ 2(6), 1–7 (2012)
N. Gupta, K.G. Satyanarayana, The solidification processing of metal-matrix composites: the Rohatgi Symposium. JOM 58, 92–94 (2006). https://doi.org/10.1007/s11837-006-0236-0
P. Ajay Kumar, P. Rohatgi, D. Weiss, 50 years of foundry-produced metal matrix composites and future opportunities. Inter Metalcast 14, 291–317 (2020). https://doi.org/10.1007/s40962-019-00375-4
S.M. Emami, M. Divandari, H. Arabi, E. Hajjari, Effect of melt-to-solid insert volume ratio on Mg/Al dissimilar metals bonding. J. Mater. Eng. Perform 22, 123–130 (2013). https://doi.org/10.1007/s11665-012-0243-y
R.K. Tayal, S. Kumar, V. Singh, A. Gupta, D. Ujjawal, Experimental investigation and evaluation of joint strength of A356/Mg bimetallic fabricated using compound casting process. Inter Metalcast 13, 686–699 (2019). https://doi.org/10.1007/s40962-018-0288-2
M. Sarvari, S. Ghaemi Khiavi, M. Divandari, H. Saghafian, Dissimilar joining of Al/Mg light metals by centrifugal compound casting process. Inter Metalcast. (2022). https://doi.org/10.1007/s40962-022-00832-7
D. Xu, C. Yang, K. Zhao, H. Li, J. Zhang, Interfacial microstructure and mechanical behavior of Mg/Cu bimetal composites fabricated by compound casting process. Trans. Nonferr. Metals Soci. China 29, 1233–1241 (2019). https://doi.org/10.1016/S1003-6326(19)65030-2
H. John, H. Hausner, Wetting of aluminum oxide by liquid aluminum. Int. J. High Technol. Cer. 2, 73–78 (1986). https://doi.org/10.1016/0267-3762(86)90006-8
S. Bao, K. Tang, A. Kvithyld, M. Tangstad, T.A. Engh, Wettability of aluminum on alumina. Metall. Mater. Trans. B 42, 1358–1366 (2011). https://doi.org/10.1007/s11663-011-9544-z
T. Noguchi, J. Kano, K. Noguchi, N. Horikawa, T. Nakamura, The enhancing effect of surface coatings on cast-in bonding of steel and titanium inserts in aluminium castings. Int. J. Cast Met. Res. 13, 363–371 (2001). https://doi.org/10.1080/13640461.2001.11819417
K.J.M. Papis, B. Hallstedt, J.F. Löffler, P.J. Uggowitzer, Interface formation in aluminium–aluminium compound casting. Acta Mater. 56, 3036–3043 (2008). https://doi.org/10.1016/j.actamat.2008.02.042
M. Schwankl, J. Wedler, C. Körner, Wrought Al - Cast Al compound casting based on zincate treatment for aluminum wrought alloy inserts. J. Mater. Process. Technol. 238, 160–168 (2016). https://doi.org/10.1016/j.jmatprotec.2016.07.001
M. Pintore, J. Wölck, T. Mittler, T. Greß, B. Tonn, W. Volk, Composite casting and characterization of Cu–Al bilayer compounds. Inter Metalcast 14, 155–166 (2020). https://doi.org/10.1007/s40962-019-00344-x
G. Xu, A.A. Luo, Y. Chen, A.K. Sachdev, Interfacial phenomena in magnesium/aluminum bi-metallic castings. Mater. Sci. Eng., A 595, 154–158 (2014). https://doi.org/10.1016/j.msea.2013.11.093
C.A. León, R.A.L. Drew, The influence of nickel coating on the wettability of aluminum on ceramics. Compos. A Appl. Sci. Manuf. 33, 1429–1432 (2002). https://doi.org/10.1016/S1359-835X(02)00161-6
Y. Hu, Y. Chen, L. Li, H. Hu, Z. Zhu, Microstructure and properties of Al/Cu bimetal in liquid–solid compound casting process. Trans. Nonferr. Metals Soci. China 26, 1555–1563 (2016). https://doi.org/10.1016/S1003-6326(16)64261-9
G. Li, W. Jiang, F. Guan, J. Zhu, Z. Zhang, Z. Fan, Microstructure, mechanical properties and corrosion resistance of A356 aluminum/AZ91D magnesium bimetal prepared by a compound casting combined with a novel Ni-Cu composite interlayer. J. Mater. Process. Technol. 288, 116874 (2021). https://doi.org/10.1016/j.jmatprotec.2020.116874
A.O. Bakke, J.-O. Løland, S. Jørgensen, J. Kvinge, L. Arnberg, Y. Li, Interfacial microstructure formation in Al7SiMg/Cu compound castings. Inter Metalcast 15, 40–48 (2021). https://doi.org/10.1007/s40962-020-00463-w
A. Rohlwing, K.K. Rane, A. Kordijazi, D. Weiss, N. Sonnentag, B. Church, P. Rohatgi, Cast-in inserts, including MMC inserts in aluminum compound castings. AFS Trans. 130, 57–73 (2022)
J. Feng, Bonding of aluminum alloys in compound casting. Metall. Mater. Trans. A 48, 4632–4644 (2017)
H. Liu, D. Fu, Z. Dong, S. Huang, H. Zhang, Bonding interfacial characterization of SiCp/8009Al composite and A356 aluminum alloy using compound casting. J. Mater. Process. Technol. 263, 42–49 (2019). https://doi.org/10.1016/j.jmatprotec.2018.08.007
J. Zhao, F. Cao, J. Sun, X. Yuan, H. Shen, X. Zhao, Impacts of zinc layer and pouring method on interface performance for Al-22Si/ZL104 bi-metal. China Foundry 14, 39–45 (2017). https://doi.org/10.1007/s41230-017-6077-3
A.M. Tavakoli, B. Nami, M. Malekan, I. Khoubrou, Influences of coating type on microstructure and strength of aluminum-steel bimetal composite interface. Inter Metalcast 16, 689–698 (2022). https://doi.org/10.1007/s40962-021-00630-7
M. Ramadan, K.M. Hafez, A.S. Alghamdi, B. Ayadi, K.S. Abdel Halim, Novel approach for using ductile iron as substrate in bimetallic materials for higher interfacial bonding bearings. Inter Metalcast 16, 987–1000 (2022). https://doi.org/10.1007/s40962-021-00653-0
ASM handbook. 2: Properties and selection: nonferrous alloys and special-purpose materials 7. Print. ASM International (2007).
Metals & alloys in the unified numbering system Thirteenth edition. SAE International: ASTM International (2017).
H. Okamoto, Supplemental literature review of binary phase diagrams: Al–Ni, B–Hf, Ca–Sc, Cr–Sc, Fe–Rh, Hf–Mn, La–Sb, Ni–Re, Ni–Sm, Ni–Zr, Sb–Tb, and Ti–Zr. J. Phase Equilib. Diffus. 40, 830–841 (2019). https://doi.org/10.1007/s11669-019-00765-5
L. Osvatic, P.Z. Flores, M. Steffes, K. Rane, S.K. Behera, D. Weiss, P.K. Rohatgi, Bond formation between aluminum-based metal matrix composites and aluminum alloys in compound castings. AFS Trans. 131, 97–105 (2023)
Acknowledgements
The authors express their gratitude to Eck Industries for providing the MMC inserts, raw materials and valuable insights during the project. This paper is based upon a presentation made at the 2023 AFS Metalcasting Congress and published in the AFS Transaction Vol. 131.29
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
This paper is based upon a presentation made at the 2023 AFS Metalcasting Congress and published in the AFS Transaction Vol. 131.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Osvatic, L., Flores, P.Z., Steffes, M. et al. Bond formation between aluminum-based metal matrix composites and aluminum alloys in compound castings. Inter Metalcast (2024). https://doi.org/10.1007/s40962-024-01270-3
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s40962-024-01270-3