Steel–Aluminum Hybrid Die Casting: Microstructures Related to the Applied Al-Si Bond Coating

Martin, Stefan; Sulik, D.; Fang, Xiang Fan; Becker, Hanka; Leineweber, Andreas

doi:10.2139/ssrn.4039449

Cited by 2 publications

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“…20-25 μm thick, which consists of a 2-3μm layer on steel substrate with fine-grained Fe-Al-Si intermetallic phase and a next second thicker layer with mainly Al and some Si. This PVD coating layer acts as an adhesion promoter, which enables the fusion between the second layer with the cast aluminium, forming a ductile material bonding [16]. The tensile tests on shear specimens produced via die casting showed an average tensile shear strength of 11 MPa and ductile behaviour [10,11], which was further confirmed by fatigue tests [17].…”

Section: Hybrid-casting Technologymentioning

confidence: 96%

Lightweight, package and performance improvements of a shock tower by using steel–aluminium hybrid-casting technique

Stolz

Fang

2022

Automot. Engine Technol.

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In this work, a shock tower of a mid-size vehicle using steel (St)–aluminium (Al) hybrid-casting technology was developed with current shock towers as a benchmark. The use of this hybrid-casting technology, which features a ductile material connection between steel and cast aluminium, makes it possible to combine the design advantages of cast aluminium with the mechanical properties of high-strength steels. Based on this combination, a new shock tower concept was developed that offers advantages over the state of the art in terms of package, weight, stiffness and crash performance. To develop the new shock tower, connection points and package spaces in the periphery of the Honda Accord MY 2011 were analysed and defined. Based on quasi-static misuse load cases and topology optimization, it was possible to develop a load-compliant rib structure for the hybrid-cast shock tower reinforced by steel in the dome area. A so-called tension band for the IIHS small overlap crashworthiness evaluation test (SOL) was also integrated into the new shock tower to ensure homogeneous load distribution. The new shock tower was tested virtually in comparison with the reference steel shock tower and an Al-cast shock tower in quasi-static and dynamic crash load cases. In the quasi-static test, the hybrid-cast shock tower showed significantly increased stiffness. In the dynamic load cases, a significant overall homogenization of force distribution on the existing load paths in die front body structure was achieved. In addition, 5 mm package space for spring and damper could be gained for better driving behaviours of the car.

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Section: Hybrid-casting Technologymentioning

confidence: 96%

Lightweight, package and performance improvements of a shock tower by using steel–aluminium hybrid-casting technique

Stolz

Fang

2022

Automot. Engine Technol.

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Dealing with Fe in Secondary Al-Si Alloys Including Metal Melt Filtration

Becker,

Leineweber

2024

Springer Series in Materials Science

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Fe is a detrimental impurity element in secondary, i. e. recycled, Al–Si cast alloys (Zhang et al. in Miner. Process. Extr. Metall. Rev. 33:99, 2012;Raabe et al. in Prog. Mater. Sci. 128, 2022;). It leads to decrease of castability and promotes crack formation due to formation of primary, Fe-containing intermetallic particles, e.g. plate-shaped β-Al–Fe–Si, coarse αh-Al–Fe–Si or αc-Al–(Fe,Mn,Cr)–Si in presence of further transition metal elements e.g. Mn and Cr. Successfully, dealing with such secondary Al–Si cast alloys contributes to sustainability, circular economy and reduction of energy consumption (Raabe et al. in Prog. Mater. Sci. 128, 2022;Taylor in Mater. Sci. Forum 689:429, 2011;). In the present chapter, a systematic understanding is provided for dealing with Fe impurities in secondary Al–Si alloys by. removal of Fe on the basis of melt conditioning and metal melt filtration and modification of Fe-containing phases into harmless microstructural components. In this context new insight is obtained into. the crystal structures of some relevant intermetallic phases occurring in secondary Al–Si alloys, thermodynamics and kinetics of phase formation during solidification and the interaction of different filter materials with the transition metal containing Al–Si alloys. The crystal structures of the β-Al–Fe–Si and δ-Al–Fe–Si phases and of their ordered variants were investigated. This allowed reliable distinction of occurring intermetallic phases, the αh-Al–Fe–Si, the αc-Al–(Fe,Mn,Cr)–Si, the β-Al–Fe–Si and the δ-Al–Fe–Si phase, especially by electron backscatter diffraction. While modification of the alloy composition by the Mn, Cr content and presence of other transition metal elements affect the thermodynamic properties of the phases, these elements also significantly affect the kinetics of phase formation during solidification at high cooling rates including the resulting phase morphology. The formation of primary, intermetallic phases during melt conditioning closely above the solidification temperature of the (Al)-solid solution can be utilized for the removal of Fe by separating the primary, Fe-containing, intermetallic particles from the Fe-depleted Al melt. Removal of such particles by application of filters to increase the Fe-removal efficiency extends the filters’ use beyond the removal of nonmetallic inclusions, contributing to production of high-quality, recycled Al–Si alloys. Evaluation of wettability, chemical reactions and microstructure in the interaction region between the filter material and Al–Si melts and the Fe-depleted melt reveals a beneficial effect of C-bonded Al2O3 filter material.

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Steel–Aluminum Hybrid Die Casting: Microstructures Related to the Applied Al-Si Bond Coating

Cited by 2 publications

References 0 publications

Lightweight, package and performance improvements of a shock tower by using steel–aluminium hybrid-casting technique

Lightweight, package and performance improvements of a shock tower by using steel–aluminium hybrid-casting technique

Dealing with Fe in Secondary Al-Si Alloys Including Metal Melt Filtration

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