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Squeeze Overcasting of Bimetallic Composite Al2026/Al–4.5%Cu with Acidic Quenching in Aging Treatment: Characterization of Mechanical Properties and Joint Interface Microstructure

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Abstract

Keeping in view the structural applications of aluminum alloys, squeeze overcasting has been considered an attractive alternative to deal with the inherent casting defects at the interface region of bimetallic composites. Microstructure at the joint interfacial region highly depends on the casting parameters. For this reason, the current study has considered the most effective parameters including melt temperature, insert preheat temperature, squeeze pressure, pressure duration and time delay to fabricate the defect-free Al2026/Al–4.5%Cu composite. Besides this, the influence of aging treatment with 5%HCl solution quenching has been investigated on yield strength, ultimate tensile strength, percentage elongation and microhardness of interfacial region of the bimetallic joint. Results of the current study show that the melt temperature and squeeze pressure are the most influential parameters to boost mechanical properties. Metallographic analysis based on SEM shows that the optimum set of input parameters (MT = 800 °C, IT = 250 °C, SP = 100 MPa, PD = 150 s, TD = 10 s) offers the strong metallurgical bond between melt and solid insert without any inherent casting defects such as micro-cracks, gas porosity, pinholes, shrinkage voids and hot tearing. EDS analysis depicts that zinc coating is highly concentrated at the interfacial region which facilitates the formation of strong metallic bonding between distinct metals.

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Abbreviations

M T :

Melt temperature

S P :

Squeeze pressure

I T :

Insert preheat temperature

P D :

Pressure duration

T D :

Time delay

YS:

Yield strength

UTS:

Ultimate tensile strength

%El:

Percentage elongation

MH:

Microhardness

SEM:

Scanning electron microscopy

EDS:

Energy-dispersive X-ray spectroscopy

GRA:

Grey relational analysis

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Acknowledgements

The authors are thankful to King Saud University for funding this work through the Researchers Supporting Project number (RSPD2023R701), King Saud University, Riyadh, Saudi Arabia.

Funding

This research was funded by Researchers Supporting Project number (RSPD2023R701), King Saud University, Riyadh, Saudi Arabia.

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Authors and Affiliations

  1. Department of Industrial Engineering, College of Engineering and Architecture, Al-Yamamah University, 11512, Riyadh, Saudi Arabia

    Naveed Ahmed & Madiha Rafaqat

  2. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Muhammad Asad Ali & Sadaf Zahoor

  3. Department of Industrial and Manufacturing Systems Engineering, The University of Hong Kong, Pok Fu Lam, Hong Kong

    Muhammad Huzaifa Raza

  4. Department of Industrial Engineering, College of Engineering, King Saud University University, 11421, Riyadh, Saudi Arabia

    Ateekh Ur Rehman

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  1. Naveed Ahmed
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Ahmed, N., Ali, M.A., Raza, M.H. et al. Squeeze Overcasting of Bimetallic Composite Al2026/Al–4.5%Cu with Acidic Quenching in Aging Treatment: Characterization of Mechanical Properties and Joint Interface Microstructure. Inter Metalcast 18, 1644–1663 (2024). https://doi.org/10.1007/s40962-023-01141-3

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