Dissimilar joining of Al/Mg light metals by compound casting process |
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Authors: | E Hajjari M Divandari S H Razavi S M Emami T Homma S Kamado |
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Affiliation: | (1) Department of Metallurgy and Materials Engineering, Iran University of Science and Technology, Tehran, 16846-13114, Iran;(2) Department of Mechanical Engineering, Nagaoka University of Technology, Nagaoka 940-2188, Japan |
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Abstract: | “Compound casting” was used for production of lightweight Al/Mg couples. In order to prepare the Al/Mg couples using this
process, each of the aluminum and magnesium molten metal was cast around solid cylindrical inserts of the other metal. After
solidification, the interfacial microstructure and shear strength of the joint were studied. Characterization of Al/Mg interface
by an optical microscope and scanning electron microscope showed that in the case of casting aluminum melt around a magnesium
insert, a gap is formed at the interface, while in the process of casting magnesium melt around an aluminum insert, a relatively
uniform interface composed of three different layers is formed at the interface. The results of the X-ray diffraction, energy
dispersive X-ray spectroscopy, wavelength dispersive X-ray spectroscopy, and microhardness analysis of the interface showed
that these three layers are mainly composed of high-hardness Al–Mg intermetallic compounds. Furthermore, it was found that
the thickness of the interface is not constant throughout Al/Mg joint, and varies gradually from 190 μm at the bottom to 140 μm
in the middle and 50 μm at the top of the sample. The results of shear strength tests obviously showed that the strength of
the interface depends on the interface thickness and increases by decreasing the thickness of the interface. |
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