Interface of steel inserts in Al-Si alloy castings

This introduction paper is based on the paper "Interface of steel inserts in Al-Si alloy castings" published by "Dissertation, Technischen Universität Wien, Fakultät für Maschinenwesen und Betriebswissenschaften".

1. Overview:

• Title: Interface of steel inserts in Al-Si alloy castings
• Author: Dipl. Ing. Karolina Monika Zimnik
• Year of publication: 2011
• Journal/academic society of publication: Dissertation, Technischen Universität Wien, Fakultät für Maschinenwesen und Betriebswissenschaften
• Keywords: Aluminium-silicon alloys, steel inserts, casting, interface characterization, solidification, residual stress, Al-Fe-Si intermetallics, gravity die casting, low pressure die casting, squeeze casting.

2. Abstract:

Aluminium alloys are very important materials because of they low density and excellent mechanical properties. Aluminium silicon casting alloys are essential to the automotive, aerospace and engineering sectors. Aluminium silicon alloys are well established for casting processes; however the silicon forms brittle needle-like particles which reduce impact resistance in cast structures. Inserts of steel or cast iron provide locally increased strength and wear resistance.
The relatively high melting temperature of iron base alloys allows placing iron parts into moulds to be surrounded by the liquid Al-melt, which solidifies embedding the insert. Steel inserts are embedded into Al-Si alloys by gravity casting, by low pressure die casting, and by squeeze casting. Oxidized and etched steel rods with different surfaces are used for the gravity casting. For the gravity casting with steel cube inserts, different thermal conditions are used: mould at RT and high temperature with Al (99.8%), AlSi7 and AlSi7Mg0.3. Insert rings of different heights are used for the low pressure die casting of a step shape. A demo-axial sample has been designed in the thesis by Bitsche to demonstrate the potential of embedding a steel insert into aluminium by squeeze casting of AlSi7Mg0.3.
The linear coefficient of thermal expansion (CTE) of Fe is roughly half of that of Al (∆CTE > 12ppm/K). During solidification, Al-alloys shrink by about 6 vol.%. The yield strength is so low just below the solidification temperature that plastic deformation will occur around an insert. Assuming that elastic stresses can build up below 275°C, the remaining misfit volume between Fe and Al amounts to about 1 vol.%. The corresponding linear length change surpasses the elastic range. The elastic stresses building up depend on the yield strength of the Al alloy at service temperature.
Magnesium additions allow precipitation hardening of the α-Al. The room temperature yield strength of pure Al is around 50MPa, that of the AlSi12 eutectic around 150MPa and after precipitation hardening the alloy by Mg2Si>200MPa.
Thus a deformation of 0.3% of the casting causes different degrees of plastic deformation and elastic stresses within the different micro-structural components of the Al alloy around the insert.
The internal stresses in the regions of Al bulk surrounding the insert part are measured by X-ray diffraction. The compressive level of 75±25MPa in the quenched α-Al Matrix without insert originates from the thermal mismatch with respect to Si. Close to the insert, tangential tensile stresses in Al are identified in the range of 100MPa. The bonding strength increases with the age hardening of the Mg-containing Al-Si alloy embedding the steel inserts with rough surfaces.
Scanning Electron Microscopy and Light Optical Microscopy are used to characterize the microstructure of the samples, particularly the interface between aluminium and steel. Interface reactions produce Al-Fe-Si phases on chemically cleaned steel but not on naturally oxidized. The Al casting consists of α-dendrites and AlSi12 eutectic in the interdendritic regions. Close to the mould, the SDA is much smaller, than in the bulk, when solidification started from the mould owing to the higher cooling rate.
Metallography gives evidence of some cracks, gas entrapment and shrinkage holes detected as well non destructively by Laser Ultrasound. Such defects increase when solidification at the interface is delayed. Summarizing, the geometry of the steel insert or surface preparation and particularly the solidification conditions for the embedding Al-alloy have significant consequence on the interface quality, like reaction bonding, gaps or porosity.
Solidification should begin along the interface, where remelting has to be avoided. Sufficient feeding has to be supplied between the solidification fronts.

3. Introduction:

Aluminium is a widely used engineering material, second only to steel, valued for its low density, strength, corrosion resistance, and recyclability. Aluminium alloys, particularly Al-Si alloys (4XXX group), are well-established for casting processes due to their excellent castability, allowing the production of complex and reliable castings. Silicon enhances fluidity, reduces melting temperature, and decreases solidification shrinkage. While Al-Si alloys offer good abrasion resistance due to hard silicon particles, cast inserts, typically made from steel or cast iron, are employed to provide better surface finish, rapid solidification, and improved local mechanical properties.
This work focuses on the microstructure of Al-alloys and the bonding between steel inserts and aluminium castings prepared by various casting processes. The interface is primarily studied using Light Optical Microscopy (LOM) and Scanning Electron Microscopy (SEM). Stress analysis is conducted using X-ray diffraction, and the influence of microstructure on bonding strength is investigated.

4. Summary of the study:

Background of the research topic:

Aluminium alloys are crucial in various industries due to their favorable properties. Al-Si cast alloys are particularly important for producing complex shapes. However, to enhance local properties like strength or wear resistance, or to combine different material functionalities, inserts (often steel) are cast into the aluminium components. The quality of the bond and the characteristics of the interface between the insert and the cast aluminium are critical for the performance of such hybrid components. Factors influencing this interface include the casting process, alloy compositions, insert material and surface preparation, and thermal conditions during casting and cooling. Differences in thermal expansion coefficients and solidification shrinkage between aluminium and steel can lead to residual stresses, gaps, or other defects at the interface.

Status of previous research:

Previous research, as reviewed in the dissertation, has covered various aspects of aluminium alloys, including their classification, strengthening mechanisms (like heat treatment and age hardening), and properties of Al-Si cast alloys. Different casting processes such as gravity die casting, low pressure die casting, and squeeze casting have been extensively studied, along with common defects like porosity and shrinkage. The effect of solidification rate on microstructure (e.g., dendrite arm spacing - SDA) and properties is also well-documented. Specific studies on cast-in inserts in magnesium and aluminium alloys have explored design considerations, the formation of intermetallic compounds at the Al/Fe interface, and the impact of processing parameters on bonding and defect formation. Techniques for microstructural characterization, thermal analysis, mechanical testing, and non-destructive evaluation of such interfaces have also been developed and applied.

Purpose of the study:

The objectives of this work, as stated on page 21, were to investigate the interface between aluminium castings and steel inserts produced by different casting processes (gravity die casting, low pressure die casting, and squeeze casting). The specific questions addressed were:

• Which casting conditions produce interface reactions, and how much?
• Do interface reactions improve the bonding?
• How much residual stresses build up in Al at the interface during casting due to CTE mismatch?
• How develops the cast microstructure of the interface to the insert?
• Which casting defects influence the interface?
• Does the bonding strength depend on the age hardening of the Al-alloy?

Core study:

The core of the study involved experimentally producing and characterizing Al-Si alloy castings with embedded steel inserts using three different casting methods: gravity die casting (rod and cube samples), low pressure die casting (step samples), and squeeze casting (demo-axial samples). Various Al alloys (Al 99.8%, AlSi7, AlSi7Mg0.3) and steel inserts (St37, 18-8 Cr-Ni, St52, C45E) with different surface conditions and geometries were used. The study focused on:

• Investigating the formation of intermetallic phases at the Al/steel interface.
• Analyzing the microstructure of the Al alloy near the interface, including dendrite arm spacing (SDA).
• Identifying and characterizing defects such as gaps, porosity, and cracks.
• Measuring residual stresses in the aluminium matrix around the insert.
• Evaluating the bonding strength through pull-out tests.
• Correlating these interface characteristics with casting parameters, thermal history, and post-casting heat treatments.
  A range of analytical techniques was employed, including LOM, SEM, EDX, XRD, thermal analysis (DSC, TMA), hardness testing, compression testing, and Laser Ultrasound (LUS) for non-destructive testing.

5. Research Methodology

Research Design:

The research was designed as an experimental study to compare the interface characteristics of steel inserts in Al-Si alloy castings produced by gravity die casting, low pressure die casting, and squeeze casting. Different insert geometries (rods, cubes, rings, tubes), Al alloys (pure Al, AlSi7, AlSi7Mg0.3), and steel grades (St37, 18-8 Cr-Ni, St52, C45E) were investigated. The influence of insert surface treatment, melt temperature, mould temperature, and post-casting thermal treatments on the interface microstructure, defect formation, intermetallic phase growth, residual stresses, and bonding strength was systematically examined.

Data Collection and Analysis Methods:

• Materials:
  • Aluminium alloys: Al (99.8%), AlSi7, AlSi7Mg0.3.
  • Steel inserts: St37, 18-8 Cr-Ni (for gravity die casting); St52 (for low pressure die casting); C45E (for squeeze casting).
  • Insert surface treatments: as-received (oxidized), etched, polished.
• Casting Processes:
  • Gravity die casting: Rod samples (St37, 18-8 Cr-Ni inserts in AlSi7) and Cube samples (St37, 18-8 Cr-Ni inserts in Al 99.8% and AlSi7Mg0.3).
  • Low pressure die casting: Step samples (St52 ring inserts in AlSi7Mg0.3).
  • Squeeze casting: Demo-axial samples (C45E shaped tube inserts in AlSi7Mg0.3).
• Thermal Treatments: Aging treatments at 165°C, 250°C, and 350°C for various durations.
• Test Methods:
  • Temperature measurements during casting.
  • Microstructural Analysis: Light Optical Microscopy (LOM) and Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray spectroscopy (EDX) for phase identification and defect analysis.
  • Hardness Testing: Brinell hardness (HB10) and micro-hardness (HV0.05).
  • Thermal Analysis: Thermomechanical Analysis (TMA) for thermal expansion and Differential Scanning Calorimetry (DSC) for phase transformations.
  • Compression Tests: Gleeble Machine 1500 to determine flow stress at elevated temperatures.
  • X-ray Diffraction (XRD) Analysis: sin²Ψ method for residual stress measurement in Al and steel. Neutron diffraction was also mentioned for AlSi7 alloy.
  • Pull-out Tests: Zwick Z050 testing machine to evaluate bonding strength of demo-axial samples.
  • Laser Ultrasound (LUS): Contactless, non-destructive method for interface defect detection in demo-axial samples.

Research Topics and Scope:

The research focused on the interface phenomena between steel inserts and Al-Si alloy castings. The scope included:

• Characterization of the Al/steel interface morphology and microstructure.
• Identification and quantification of intermetallic compound (IMC) layers (e.g., Al-Fe-Si phases).
• Analysis of casting defects at or near the interface (porosity, shrinkage cavities, gaps, cracks).
• Investigation of the influence of casting parameters (melt/mould temperature, cooling rate, pressure) on interface quality.
• Study of the effect of insert material, geometry, and surface preparation.
• Measurement of residual stresses resulting from thermal mismatch and phase transformations.
• Evaluation of the mechanical integrity of the bond, particularly the effect of age hardening on bonding strength.
• Application of non-destructive testing (LUS) for interface quality assessment.
  The study covered three main casting techniques: gravity die casting, low pressure die casting, and squeeze casting.

6. Key Results:

Key Results:

The study yielded comprehensive insights into the interface formation and characteristics of steel inserts in Al-Si alloy castings under various processing conditions.

• Solidification and Microstructure:
  • The AlSi7 castings typically consisted of α-Al dendrites and Al-Si eutectic. Secondary Dendrite Arm Spacing (SDA) varied significantly (5-75µm in rod samples, <3-20µm in step samples, 8-80µm bimodal in demo-axial samples) depending on local solidification rates, which were influenced by mould temperature, insert temperature, and casting section thickness.
  • Cooling rates in step samples varied from ~40K/s (near steel insert, thick Al section) to 160K/s (thin Al section, near mould).
  • Interface microstructure varied from 20 to 30 vol% of AlSi12 eutectic, with higher concentrations sometimes indicating macro-segregation.
• Interface Reactions and Intermetallic Compounds (IMCs):
  • Interface reactions forming Al-Fe-Si phases occurred primarily on chemically cleaned (oxide-free) steel surfaces. The extent of reaction was more significant with pure Al than with Al-Si alloys.
  • In gravity cast rod samples (AlSi7/St37), IMC islands (5-115µm) formed on the steel side. For cube samples (Al/St37, RT mould), IMCs (10-13µm) formed along the entire interface.
  • Naturally oxidized steel inserts generally did not show significant reaction layers within usual solidification periods.
• Casting Defects:
  • Shrinkage holes, gaps, and porosity were common interface defects, particularly when solidification at the interface was delayed or remelting occurred.
  • Gas entrapment was frequently observed in step samples (LPDC), leading to gaps.
  • In gravity cast cube samples, poor bonding and large gaps were observed if the melt solidified too fast at the steel surface (e.g., hot mould for AlSi7Mg0.3 without proper feeding) or if shrinkage was not compensated.
  • Squeeze casting (demo-axial samples) showed potential for good bonding, but defects like filling porosity could still occur in the bulk Al.
• Residual Stresses:
  • X-ray diffraction revealed compressive stresses (typically 70±20MPa in α-Al) in the Al-Si matrix after quenching, originating from thermal mismatch with Si particles.
  • Near the steel insert, tangential tensile stresses up to 100MPa (or 40MPa tension, an increase of ~110MPa over bulk) were measured in the Al of step samples, attributed to the CTE mismatch between Al and steel. Radial compressive stresses were around -90 ± 30MPa.
  • In the demo-axial sample (AlSi7Mg0.3/C45E), residual stresses were measured.
• Bonding Strength and Mechanical Properties:
  • The yield strength of AlSiMg alloys decreased linearly with increasing temperature (e.g., from ~180MPa at 110°C to ~20MPa at 500°C).
  • Pull-out tests on demo-axial samples showed that bonding strength was influenced by heat treatment. Age hardening of the AlSi7Mg0.3 alloy (e.g., 165°C/2.5h, YS ~190MPa) improved the bonding strength, likely due to increased shrink-fit pressure and mechanical interlocking. The highest pull-out force (26kN for sample 22) was observed for a peak-aged sample.
  • Hardness of AlSi7Mg0.3 varied with thermal conditions; aging at 165°C increased hardness, while higher temperature treatments (e.g., 350°C) or solution treatment reduced it.
• Non-Destructive Testing (LUS):
  • Laser Ultrasound (LUS) successfully detected debonding and delamination at the interface of demo-axial samples (steel tube/AlSi7Mg0.3). Defects were identified by variations in signal amplitude and arrival times of ultrasonic waves. LUS proved useful for characterizing interface quality, especially for tubular inserts.

Figure Name List:

• Figure 4.1 Graph of the cooling rates from 530 to 150°C at different positions in the step sample
• Figure 4.25 LOM of the rod sample 2 according to the positions indicated Figure 4.25 R (showing interface gaps, shrinkage)
• Figure 4.39 SEM micrographs showing intermetallic islands on the cross section of the rod sample 5
• Figure 4.41 Shows the intermetallic phases of the cube sample 2 (mould at RT)
• Figure 4.43 SEM micrographs showing intermetallic reactions of the cube sample 3 (AlSi7 cast, mould at the 700°C)
• Figure 4.63 Stress analysis by X-ray diffraction of the Al in the cast alloy quenched from 350°C along a radial line from the steel interface compared with stress values measured in AlSi7 without steel insert
• Figure 4.67 Pull out test of the steel tubes from the as cast and heat treated demo-axial sample: force versus displacement curves
• Figure 4.69 [70] Shows A) Scan along the surface with the position of the minimum shown, B) Ultrasonic raw data of one 360° scan (LUS results)

7. Conclusion:

The AlSi7 castings consist of α-dendrites and eutectic Al-Si, with secondary dendrite arm spacing (SDA) varying from 5-75µm, reflecting local solidification rates. Finer dendrite structures were observed near cold moulds or cold steel inserts. Interface microstructures varied, containing 20-30 vol% AlSi12 eutectic. Cooling rates for step castings ranged from 40K/s to 160K/s.

Steel inserts in Al castings exhibited interface defects like shrinkage holes, gaps, and porosity, especially where the alloy solidified last or was remelted. Gas entrapment was common in LPDC step samples. Interface reactions forming aluminides occurred with oxide-free steel, more significantly with pure Al than Al-Si alloys. Mechanical bonding appeared better with localized interface reactions.

Residual stresses in Al-Si alloys showed significant compressive stress (70±20MPa in α-Al) after quenching due to thermal mismatch with Si. Near steel inserts, circumferential tensile stresses (e.g., 40MPa tension, a change of ~110MPa) were measured due to Al shrinkage relative to steel. The yield strength of AlSiMg decreased with temperature; embedding strength seems provided by insert surface roughness. Age hardening of AlSi7Mg alloy (to ~190MPa YS) improved bonding strength.

Laser Ultrasound proved effective for non-destructive testing of tubular insert interface quality. The quality of bonding depends mainly on the casting method. Solidification starting from the steel insert is desirable but competes with solidification from the mould. LPDC produced interfaces with the fewest defects. High bonding strength is achieved by mechanical interlocking (e.g., machining grooves) in the absence of defects, with elastic shrink fitting providing additional bonding.

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9. Copyright:

• This material is a paper by "Dipl. Ing. Karolina Monika Zimnik". Based on "Interface of steel inserts in Al-Si alloy castings".
• Source of the paper: http://www.ub.tuwien.ac.at/englweb/ (The approved original version of this thesis is available at the main library of the Vienna University of Technology)

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