Influence of thermo-mechanical joining process on the microstructure of a hypoeutectic aluminium cast alloy

Influence of thermo-mechanical joining process on the microstructure of a hypoeutectic aluminium cast alloy

Thomas Borgert, Moritz Neuser, Eugen Wiens, Olexandr Grydin, Werner Homberg, Mirko Schaper

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Abstract. Requirements of multi-material construction involve adjustments to standard joining techniques. Especially the growing importance of integral cast components poses additional engineering challenges for the industry. One approach to achieve these goals are adaptable joining elements formed by friction spinning. This approach uses friction-induced heat to form customisable joining elements to join sheets for different boundary conditions, even for brittle cast materials. It is possible to react immediately to adapt to the joining process inline and reduce the amount of different joining elements. As the joining partner serve casting plates of the aluminium casting alloy EN AC–AlSi9, which is processed in the sand casting. Joining hypoeutectic AlSi alloys constitutes a challenge because the brittle character of these cause cracks in the joint during conventional mechanical joining. Furthermore, the friction-induced heat of the novel joining process causes a finer microstructure in the hypoeutectic AlSi9 casting alloy. In particular, the eutectic Si is more fine-grained, resulting in higher joint ductility. This study indicates the joining suitability of a hypoeutectic aluminium casting alloy in combination with adaptive manufactured additional joining elements. Here, various mechanical and microstructural investigations validate the influence of the thermomechanical joining technique. In conclusion, the potential of this joining process is presented regarding the joinability of cast aluminium components.

Joining, Casting, Microstructure

Published online 3/17/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: Thomas Borgert, Moritz Neuser, Eugen Wiens, Olexandr Grydin, Werner Homberg, Mirko Schaper, Influence of thermo-mechanical joining process on the microstructure of a hypoeutectic aluminium cast alloy, Materials Research Proceedings, Vol. 25, pp 187-194, 2023


The article was published as article 24 of the book Sheet Metal 2023

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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