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Interface Characterization, Thermal and Mechanical Properties Evaluation of Cu, Zn, and Sn Interlayered Al5.2Si alloy-SS 304 Bimetallic Castings

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Abstract

Al-5.2Si is a wrought aluminium alloy having very strong corrosion resistance with high specific strength and good fluidity during casting process. Compound casting method was used to cast Al 5.2Si alloy over SS304 pipe (with Cu, Zn and Sn interlayers) to produce Al alloy-SS Bimetallic Castings (BmCs). Comparative study on bond integrity, hardness and bond strength of the produced BmCs were done by characterizing using optical microscopy, Scanning Electron Microscopy (SEM), Vickers micro hardness test and shear punch testing. The phase analysis in the interface of the produced bimetallic castings was done from the results obtained from X-ray Diffraction (XRD) and SEM with Energy Dispersive Spectroscopy (SEM/EDS). Cu-rich intermetallic compound was observed in Cu interlayered casting which showed higher hardness (74.3 HV) values at the interface. However, the reduced bond strength was found in the above BmCs due to its brittle nature. Conversely, the maximum load-bearing capacity of 39 kN was observed in the Sn interlayered casting, while Zn and Cu interlayered casting showed 33 kN and 26 kN respectively. The highest value of thermal conductivity was observed in the Sn interlayered BmC (increase in 76%) may be due to the formation of continuous reaction layer at the interface having solid solutions of Sn with Fe, Cr and Al. This confirms that this Sn interlayered Al5.2Si - SS 304 bimetallic castings may be used as a candidate material for transition joints in automotive and aerospace applications.

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All data generated or analyzed during this study are included in this submitted manuscript.

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Acknowledgements

The authors would like to thank the Management and Principal of PSG College of Technology, Coimbatore, Tamilnadu, India for providing facilities to carry out the project.

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Authors and Affiliations

  1. Department of Production Engineering, PSG College of Technology, Avinashi Road, Peelamedu, Coimbatore, Tamil Nadu, 641004, India

    V. Raja

  2. Department of Metallurgical Engineering, PSG College of Technology, Coimbatore, India

    M. Kavitha

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Raja V – Conceptualization, Experimentation, Investigation, Original draft preparation. Kavitha M – Supervision and Methodology.

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Correspondence to V. Raja.

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Raja, V., Kavitha, M. Interface Characterization, Thermal and Mechanical Properties Evaluation of Cu, Zn, and Sn Interlayered Al5.2Si alloy-SS 304 Bimetallic Castings. Silicon 15, 8009–8018 (2023). https://doi.org/10.1007/s12633-023-02653-7

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