Multi-Material Metal Casting (ACRC Funded)

Part 1: Understanding the solid-liquid reaction system – Developing a method to promote a metallurgical bond the system needs to be understood and the following needs to be mapped:

  • Thermodynamics
    A thermodynamical approach will help to give an understanding to which intermetallics should form. By complementing the theoretical work with experimental work the intermetallics that forms can be determined. This will help to correlate the properties of the bond to wanted or unwanted intermetallics as well as determining some of the effect of the kinetics of intermetallic formation
  • Kinetics
    Investigating the relationship of temperature and time on growth of the intermetallic layer the kinetics can be determined. The information on the kinetics will help to determine which processes are feasible in forming the metallurgical bond during dissimilar metal casting.
  • Energetics
    Knowing the energetics of the reactions occurring in the system the information can complement the kinetics in making a reliable process map that can show which casting processes will be more suitable for metallurgical bond formation.

Part 2: Determination of mechanical and physical properties – Once a method to establish a metallurgical bond has been developed the properties needs to be evaluated. Mechanical bond properties of interest include tensile strength, shear strength, and hardness. Physical properties of interest are thermal expansion and conductivity.

The scope of this project is to develop a ferrous insert that promotes the growth of a strong metallurgical bond with the aluminum during the casting process