Sn-Aided Joining of Cast Aluminum and Steel Through a Compound Casting Process

Abstract Obtaining a strong bond between aluminum and steel is challenging due to poor wettability melt brittle intermetallic phases forming in the interface. In this research, novel coating method, namely hot dipping of Sn, has been developed treat insert surfaces. Results show that without preheating mold or Sn-coated insert, thin, crack-free, continuous metallurgical bonding layer was achieved A356 aluminum/steel compound castings. Intermetallic structures interface have characterized detail. The Sn-coating completely melted mixed with liquid during casting process. reaction at composed ternary Al–Fe–Si particles thin binary Al 5 Fe 2 phase thickness less than 1 µ m. A small fraction dispersed Sn-rich observed distributing adjacent eutectic Si alloy. sessile drop wetting test showed substrates can be well wetted by melt. improved alloy attributed penetration breaking oxide surface droplets Sn. Graphic