The mixtures of machined cast iron (FC300) chips and graphite (Gr.) powder with 3~10mass% Gr contents were mechanically alloyed (MA) up to 36ks. The obtained MA powder was mixed with polypropylene (PP) and paraffin wax (WAX) as the binder. Then it was stacked on a cast iron (FC300) plate as the substratum and hot-pressed at 893Kat various pressures to realize debinding and preforming. Subsequently, it was sintered at 973~1273K for 1.8ks, for the bonding of the MA alloy and FC300 plate. For the estimation of bonding characteristics, the structural change due to the sintering of the bonded MA alloy layer and the hardness distribution near the bonding interface were investigated. Rupture strength in a three-point-bending test was also investigated. The structure of the sintered MA alloy layer consists of a fine ferrite phase and graphite of nanometer-order size. The structure is the same as the MA powder. However, the hardness of the MA alloy layer decreases after sintering. The rupture strength of the cast-iron-bonded MA alloy is higher than that of cast iron without the MA alloy layer. Shot peening treatment was carried out on the surface of the MA alloy layer. The surface hardness of the MA alloy layer increases with the shot peening treatment.
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