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Affiliation(s)

Institute of Automotive Lightweight Design, University of Siegen, Siegen 57076, Germany

ABSTRACT

Hybrid casting is a well known technology to join steel inserts and Aluminum. State of the art is to produce force and form locked connections, since the material based connection is very brittle. In the current work, a new metal coating concept has been developed based on the recent development of intermetallic alloys and surface coatings for Fe-Al-X-system. The new PVD coating consists of two sub-layers. The first layer is less than 3 μm in thickness and consists of Fe, Si as well as lower Al-content. A second layer consists of only Al and Si. For developed process parameters of die casting and Al-alloy, a reproducible material based connection with more than 10 MPa shear tensile stress and ductile behavior could be produced. Based on SEM (Scanning electron microscopy)study on coating layer morphology and composition as well as fracture surface, the mechanisms for the new material joining have been investigated. The special chemical composition, the thicknesses of the new coating layer in combination with the casting conditions are found to be responsible for the ductile behavior of the joining between steel and Aluminum. For the first time, there is a chance to apply steel Aluminum hybrid casting technique on real products.

KEYWORDS

Hybrid casting, Fe-Al-intermetallic phase, interfacial diffusion reaction, coating systems, die casting process, material based joining, ductile fracture.

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