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On the Steel–Aluminum Hybrid Casting by Sand Casting

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Abstract

Hybrid casting is a well-known technology to join steel inserts and aluminum. In order to achieve a high-performance material-based joining between steel and aluminum, a new PVD Al-Si-(Fe) coating, which consists of two sub-layers, has been successfully developed for high-pressure die casting. This coating system has been investigated further in this work for the sand casting process. By extending the sand casting process to the plaster casting process with preheating possibilities for the coated steel inserts, a material-based connection between steel and aluminum with a tensile shear strength of 7.7 MPa could be created. The ductility of this connection is decreased comparing with the connection manufactured by die casting. SEM and EDS analysis and diffusion experiments show that the difference of mechanical properties between plaster and die casting is caused by the extensive diffusion and the corresponding layer growth at plaster casting. The edge separation in plaster casting is a result of the edge stresses due to the different thermal expansion of steel and aluminum which can be suppressed at high-pressure die casting. To improve the joining properties at sand casting, it is necessary to control the layer diffusion by adding other alloy elements such as Mn into the Al-Si-(Fe) coating layer.

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Acknowledgments

The authors thank Mrs. Azim, Mrs. Auf dem Brinke and Mr. Heßling for their technical assistance. This work was funded by the state government of Nordrhein-Westfalen, Germany, within the “Ziel 2” program.

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Authors and Affiliations

  1. Institute of Automotive Lightweight Design, University of Siegen, Siegen, Germany

    Xiangfan Fang & Jannis-Jeremias Schipperges

  2. Grunewald Ltd, Bocholt, Germany

    Joachim Gundlach

  3. Institute of Surface and Materials Technology, University of Siegen, Siegen, Germany

    Xin Jiang

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  1. Xiangfan Fang
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  2. Joachim Gundlach
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  3. Jannis-Jeremias Schipperges
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  4. Xin Jiang
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Correspondence to Xiangfan Fang.

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Fang, X., Gundlach, J., Schipperges, JJ. et al. On the Steel–Aluminum Hybrid Casting by Sand Casting. J. of Materi Eng and Perform 27, 6415–6425 (2018). https://doi.org/10.1007/s11665-018-3717-8

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  • DOI: https://doi.org/10.1007/s11665-018-3717-8

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