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National Engineering Research Center of Light Alloys Net Forming and State Key Laboratory of Metal Matrix Composite, Shanghai Jiao Tong University, 200030 Shanghai, PR China
General Motors Global Powertrain Engineering, 823 Joslyn Avenue, Pontiac, MI 48340-2920, USA
a r t i c l e
i n f o
Article history:
Received 29 September 2014
Accepted 26 November 2014
Available online 4 December 2014
Keywords:
Aluminum alloy
Squeeze casting
Interface
Microstructure
Mechanical properties
a b s t r a c t
Aluminumaluminum bimetal were prepared by casting liquid A356 aluminum alloy onto 6101
aluminum extrusion bars and solidifying under applied pressure. The effect of surface treatment, pouring
temperature and applied pressure on microstructure and mechanical properties of the bimetal was investigated. The results showed that sound metallic bonding could be produced by electro-plating the solid
6101 aluminum alloy with a layer of zinc coating and carefully controlling the casting temperature. With
the application of pressure during solidication process, the tensile strength exhibited more promising
results than that made by gravity casting, for both A356 aluminum alloy matrix and bimetal. However,
with the increase of applied pressure, A356 aluminum alloy matrix and bimetal showed different behaviors. For A356 aluminum alloy matrix, the tensile strength increased with the increase of applied pressure, for bimetal it appeared to be independent on the magnitude of the applied pressure and the
value remained steady. The fracture analysis indicated that during the tensile test of bimetal, the crack
initiation began with initial fracture of eutectic Si in the transition zone then extended in the transition
zone. The tensile strength of the bimetal fabricated by squeeze casting method was improved by about
10%, from 145 MPa to 155 MPa, as compared with that made by gravity casting. The process presented
in this study provides a promising and effective approach to create a metallic bonding between an
aluminum insert and various aluminum melts to develop advanced functional and structural materials.
2014 Elsevier Ltd. All rights reserved.
1. Introduction
Light metal castings have been extensively used in the automotive and aerospace industries for lightweight applications [1,2].
When one single light material alone does not satisfy the requirements of high performance and efciency at low cost, bimetallic
design and manufacturing appears to be an ideal solution. Compound casting is dened as a production technology where two
metals, one in solid state while the other in liquid state, are
brought into contact with each other and thus a continuous metallic transition occurs from one metal to the other [3]. Because of its
high efciency and low cost, this method has drawn great attention in a variety systems, such as magnesium alloy and aluminum
alloy [46], aluminum alloy and cast iron [7], aluminum alloy and
copper [8,9], gray iron and copper [10], magnesium alloy and
magnesium alloy [11]. However, the application of this method is
Corresponding author at: National Engineering Research Center of Light Alloys
Net Forming, Shanghai Jiao Tong University, 800, Dongchuan Road, Shanghai
200240, PR China. Tel.: +86 21 54742715; fax: +86 21 34202794.
E-mail address: wangqudong@sjtu.edu.cn (Q. Wang).
http://dx.doi.org/10.1016/j.matdes.2014.11.051
0261-3069/ 2014 Elsevier Ltd. All rights reserved.
Surface treatment
Pouring
temperature (C)
Applied
pressure (MPa)
Degreased
Zinc treated
5 lm zinc coating
10 lm zinc coating
700
30
5 lm zinc coating
660
740
30
5 lm zinc coating
700
10
50
Table 1
The chemical compositions of the materials (wt.%).
Alloys
A356
6101
Cu
Mg
Mn
Zn
Fe
Ti
Other
Al
7.5
0.49
0.2
0.23
0.4
0.92
0.1
0
0.1
0
0.2
0.45
0.2
0
0
0
0.15
0.1
Bal
Bal
Fig. 1. Schematic illustration of the mold (a) and the tensile specimens in mm (b).
10
Fig. 5. The fractured surfaces and the cross section views of the
fractured specimen are presented in Fig. 6. For bimetal made under
degreased and zinc treated conditions, the A356 aluminum alloy
and 6101 aluminum alloy are partially metallic bonded, the tensile
strengths are very low. While for bimetal made with the 6101 aluminum alloy electro-plated with 5 lm or 10 lm zinc layer, the tensile strength are about 155 MPa. The fracture occurs in the
transition zone along the interface. There is not much difference
in tensile strength when the thickness of zinc coating varied from
5 lm to 10 lm.
3.2. Effect of pouring temperature on microstructure and mechanical
properties of bimetal
In the formation of the metallic bonding between two different
aluminum alloys, the pouring temperature needs to be controlled
precisely. The microstructures of A356 aluminum alloy6101 aluminum alloy bimetals prepared at different pouring temperature
are presented in Fig. 7. The applied pressure was kept at 30 MPa,
and the 6101 aluminum alloy inserts were electro-plated with
5 lm zinc coating. The SEM micrographs of the interface region
along with the corresponding concentration maps of element Si,
Zn and O for each sample are shown in Fig. 8. When the pouring
temperature was low, there was a clear interface between the
two aluminum alloys, beside, element Zn and O tended to aggregate along the interface. When the pouring temperature was high,
the 6101 aluminum alloy inserts would melt into the A356 molten
metal. Only when the pouring temperature was controlled at
around 700 C, the metallic bonding between A356 aluminum
alloy and 6101 aluminum alloy could be realized.
The results of Vickers hardness across the interface and tensile
strength are presented in Figs. 9 and 10 respectively. For bimetal
made at pouring temperature of 660 C, the A356 aluminum alloy
and 6101 aluminum alloy are partially metallic bonded, the Vickers
hardness changes from 5565 to 8595 abruptly and the tensile
strength is about 20 MPa. The desired metallic bonding can be
achieved when the pouring temperature is 700 C, the Vickers
hardness changes gradually across the interface and the tensile
strength is about 155 MPa.
3.3. Effect of applied pressure on microstructure and mechanical
properties of bimetal
Solidication under pressure is the most distinctive feature of
squeeze casting. The effect of applied pressure (ranging from
10 MPa to 50 MPa) on microstructure and mechanical properties
of A356 aluminum alloy6101 aluminum alloy bimetals was
investigated.
Fig. 11 presents the microstructures of interface region for samples made under different applied pressures, which were prepared
at pouring temperature of 700 C, and the 6101 aluminum alloy
inserts were electro-plated with 5 lm zinc coating. Sound metallic
bonding between A356 aluminum alloy and 6101 aluminum alloy
can be realized for all three bimetals. There is no aggregation of
element O or Zn, and no defects or discontinuities are detected.
The results of Vickers hardness for bimetal made under different applied pressure are shown in Fig. 12. As can be observed,
the hardness changes gradually across the interface. The hardness
of 6101 aluminum alloy stays in the range of 5565, the hardness
of transition zone stays in the range of 6575, while the hardness
of A356 aluminum alloy increases gradually with the increase of
the applied pressure. The results of tensile strength are presented
in Fig. 13. With the application of pressure during solidication
process, the tensile strength exhibits more promising results than
that made by gravity casting, for both A356 aluminum alloy matrix
and bimetal. However, with the increase of applied pressure, A356
11
Fig. 2. Microstructures of the interface region of bimetals made at different surface treatment conditions (a and b, degreased, c and d, zinc treated, e and f, 5 lm zinc coating,
g and h, 10 lm zinc coating).
6101 aluminum alloy inserts after the zinc coating was dissolved
into the molten metal [13]. The surface region of the 6101 aluminum alloy inserts melted partially due to the heat. Then the 6101
aluminum alloy inserts served as the heterogeneous nucleation
substrate for the primary a-Al phase [23,24], undercooling was
developed in the molten metal, a-Al dendrites started to grow
from the 6101 aluminum alloy side towards the A356 aluminum
alloy side, which parallels to heat ow but in the opposite direction. It is believed that the local fusion determines the formation
of a sound metallic bonding [25].
For bimetals made under different surface treatment, the
degreased samples exhibited poor performance because of the
existence of the oxide layer. The same phenomenon was observed
12
Fig. 3. SEM micrographs of the interface region along with the corresponding concentration maps of element Si, Zn and O for bimetals made at different surface treatment
conditions (a0a3, degreased, b0b3, zinc treated, c0c3, 5 lm zinc coating, d0d3, 10 lm zinc coating).
Fig. 4. Hardness proles measured across the interface region for bimetals made at
different surface treatment conditions.
Fig. 5. Tensile strength for bimetals made at different surface treatment conditions.
for zinc treated sample, because the 300500 nm thick zinc coating
alone was insufcient. During experiments, the thin zinc layer will
evaporate and reoxidation of the aluminum insert will occur [12].
Electro-plating method was thus introduced to increase the thickness of the zinc layer. Under this condition, metallic bonding can
be successfully produced. For pouring temperature, when operated
13
Fig. 6. Fractured surfaces and the cross section views of the fractured specimens made at different surface treatment conditions (a and b, degreased, c and d, zinc treated, e
and f, 5 lm zinc coating, g and h, 10 lm zinc coating).
14
Fig. 7. Microstructures of the interface region of bimetals made at different pouring temperatures (a and b, 660 C, c and d, 700 C).
Fig. 8. SEM micrographs of the interface region along with the corresponding concentration maps of element Si, Zn and O for bimetals made at different pouring
temperatures (a0a3, 660 C, b0b3, 700 C).
K gap
X gap
where Kgap is the average thermal conductivity of the gas in the gap,
Xgap is the gap size. With the application of the pressure during
solidication the gap between the mold and the solidied shell
decreases dramatically. Thus the heat transfer coefcient and the
DT f T f V l V s
DP
DH f
DHf
P P0 exp
RT f
Fig. 9. Hardness proles measured across the interface region for bimetals made at
different pouring temperatures.
where P0, DHf and R are constants. With the increase of pressure P,
Tf should increase, thus inducing a high undercooling compared to
conventional casting process. So when the A356 aluminum alloy
is solidied under pressure, the tensile strength is higher than that
of made by gravity casting.
15
Fig. 10. Tensile strength for bimetals made at different pouring temperatures.
The phase diagram also changes with the application of pressure. Applied pressure has an effect on the equilibrium phase by
shifting the liquidus and solidus lines, and by changing the eutectic
composition. In the AlSi alloy system, the eutectic point is shifted
toward higher concentration of Si as applied pressure increases
[34,35]. As a result, for hypoeutectic AlSi alloy, with the increase
Fig. 11. Microstructures of the interface region of bimetals made at different applied pressures (a and b, 10 MPa, c and d, 30 MPa, e and f, 50 MPa).
16
Fig. 12. Hardness proles measured across the interface region for bimetals made
at different applied pressures.
and the hardness value did not change, therefore, to increase the
applied pressure in order to further increase the tensile strength
of bimetal seems to be unnecessary in this circumstance.
It is widely accepted that for aluminumaluminum bimetal, the
tensile fracture will be located in the alloy with lower tensile
strength, while the interface region remains well [2325]. Interestingly, in this study the results were quiet different that the fracture
was located in the transition zone. However, there is no controversy between these two results. Because in the study mentioned
above, the bimetals were received in gravity casting state. The
interface region is solid solution strengthened by the interdiffusion
effect and the microstructure is more compact in transition zone.
During tensile test, fracture occurs when the UTS of the alloy with
lower strength is reached. While in the present study, the bimetal
were prepared with squeeze casting method. The alloy with lower
strength is A356 aluminum alloy, and its tensile strength increased
signicantly because of the applied pressure. The transition zone,
on the other hand, was still received in gravity casting state
because of the high solidication velocity. So during the tensile
test, the crack initiation began with initial fracture of eutectic Si
in the transition zone then extended in the transition zone, while
the A356 aluminum alloy part and 6101 aluminum alloy part
remains well. However, compared with that made by gravity casting, the tensile strength of the bimetal is improved by about 10%.
5. Conclusions
In this study, the A356 aluminum alloy-6101 aluminum alloy
bimetal were successfully fabricated by squeeze casting process.
The effect of surface treatment, pouring temperature and applied
pressure on microstructure and mechanical properties of the bimetal were investigated. The following conclusions were obtained:
Fig. 13. Tensile strength for bimetals and A356 aluminum alloy matrix made at
different applied pressures.
Acknowledgment
The authors gratefully acknowledge the nancial support of the
General Motors Company in Pontiac, USA.
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