Aluminium–aluminium compound fabrication by high pressure die casting

This study examines the development of aluminium–aluminium compounds during high pressure die casting. An aluminium insert was mounted into a die casting mould and embedded into an aluminium casting alloy. Prior to that, the natural oxide layer of the insert was removed and replaced by zinc coatings with different thicknesses. During the casting process the zinc layer dissolves and a transition zone with elevated zinc concentration and hardness forms between insert and casting alloy. The thickness of the initial Zn layer determines width and composition of the transition zone, but not the mechanical properties of the compound. The formation of a sound metallic bonding is crucial for the plastic behaviour.

► We integrate aluminium wrought alloy inserts into aluminium die castings.
► We deposit a Zn layer onto the insert's surface prior to the integration.
► A transition zone forms between both components during casting.
► The transition zone varies with varying initial Zn layer thickness.
► The mechanical properties are primarily dependent on the insert's material.