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Investigation on the Interface Characteristics of Al/Mg Bimetallic Castings Processed by Lost Foam Casting

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Abstract

The lost foam casting (LFC) process was used to prepare the A356 aluminum and AZ91D magnesium bimetallic castings, and the interface characteristics of the reaction layer between aluminum and magnesium obtained by the LFC process were investigated in the present work. The results indicate that a uniform and compact interface between the aluminum and magnesium was formed. The reaction layer of the interface with an average thickness of approximately 1000 μm was mainly composed of Al3Mg2 and Al12Mg17 intermetallic compounds, including the Al3Mg2 layer adjacent to the aluminum insert, the Al12Mg17 middle layer, and the Al12Mg17 + δ eutectic layer adjacent to the magnesium base. Meanwhile, the Mg2Si intermetallic compound was also detected in the reaction layer. An oxide film mainly containing C, O, and Mg elements generated at the interface between the aluminum and magnesium, due to the decomposed residue of the foam pattern, the oxidations of magnesium and aluminum alloys as well as the reaction between the magnesium melt and the aluminum insert. The microhardness tests show that the microhardnesses at the interface were obviously higher than those of the magnesium and aluminum base metals, and the Al3Mg2 layer at the interface had a high microhardness compared with the Al12Mg17 and Al12Mg17 + δ eutectic layers, especially the eutectic layer.

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Acknowledgments

This work was funded by Project 51204124 supported by the National Natural Science Foundation of China, Project P2015-09 supported by State Key Laboratory of Materials Processing and Die & Mould Technology, HUST, and Project 2012M511610 & 2014T70694 supported by the China Postdoctoral Science Foundation. The authors would also like to thank the support of the Research Project of State Key Laboratory of Materials Processing and Die & Mould Technology and the Analytical and Testing Center, HUST.

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Authors and Affiliations

  1. State Key Lab of Materials Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan, 430074, P.R. China

    Wenming Jiang (Associate Professor), Guangyu Li (Graduate Student), Zitian Fan (Professor), Long Wang (Graduate Student) & Fuchu Liu (Graduate Student)

  2. School of Mechanical & Electrical Engineering, Wuhan Institute of Technology, Wuhan, 430074, P.R. China

    Wenming Jiang (Associate Professor)

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  1. Wenming Jiang
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  2. Guangyu Li
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Correspondence to Wenming Jiang.

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Manuscript submitted August 8, 2015.

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Jiang, W., Li, G., Fan, Z. et al. Investigation on the Interface Characteristics of Al/Mg Bimetallic Castings Processed by Lost Foam Casting. Metall Mater Trans A 47, 2462–2470 (2016). https://doi.org/10.1007/s11661-016-3395-9

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