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Design and Processing of Bimetallic Aluminum Alloys by Sequential Casting Technique

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Abstract

Sequential casting is a facile and fairly new technique to produce functionally graded materials (FGMs) and components by controlled mold filling process. In the present investigation, functionally graded bimetallic aluminum alloys are produced by sequential gravity casting using A390–A319 and A390–A6061 alloy combinations. The control in pouring time between two melts has shown a significant effect on the quality and nature of interface bonding. The microstructure reveals good interface miscibility achieved through diffusion bonding between the alloys. A higher hardness of 160 BHN in the A390 region is obtained in both sequential cast systems, and a minimum value of 105 and 91 BHN is observed in the A319 and A6061 regions, respectively. The tensile and compression strength for A390–A319 are 337 and 490 MPa, whereas for A390–A6061, they are 364 and 401 MPa, respectively, which are significantly higher compared with the standard values of the base alloys, which confirms strong interface bonding. The A390 region shows higher wear resistance compared with other regions of the sequential cast system. The process described in this study is a potential and efficient approach to create good bonding between two different aluminum alloys to develop advanced functional and structural materials.

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Acknowledgments

The authors are indebted to the Director of CSIR-NIIST and to the members of the Materials Science and Technology Division (MSTD), CSIR-NIIST, Thiruvananthapuram, as well as to CSIR for the ESC-0101 project funding.

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Authors and Affiliations

  1. CSIR-National Institute for Interdisciplinary Science and Technology, Thiruvananthapuram, Kerala, 695019, India

    Akhil S. Karun (Research Scholar), S. Hari (Research Scholar), T. P. D. Rajan (Senior Scientist), U. T. S. Pillai (Chief Scientist) & B. C. Pai (Emeritus Scientist)

  2. Discipline of Mechanical Engineering, Howard CollegeUniversity of KwaZulu-Natal, Durban, 4000, South Africa

    Williams S. Ebhota (Chief Engineer)

Authors
  1. Akhil S. Karun
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  2. S. Hari
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  3. Williams S. Ebhota
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  4. T. P. D. Rajan
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  5. U. T. S. Pillai
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  6. B. C. Pai
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Corresponding authors

Correspondence to Akhil S. Karun or T. P. D. Rajan.

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Manuscript submitted May 31, 2016.

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Karun, A.S., Hari, S., Ebhota, W.S. et al. Design and Processing of Bimetallic Aluminum Alloys by Sequential Casting Technique. Metall Mater Trans A 48, 279–293 (2017). https://doi.org/10.1007/s11661-016-3824-9

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  • DOI: https://doi.org/10.1007/s11661-016-3824-9

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