Design and Processing of Bimetallic Aluminum Alloys by Sequential Casting Technique
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IONALLY graded materials (FGMs) are the nonuniform advanced class of alloy or composite materials that exhibit a gradual transition in the microstructure or in the composition with continuous changing properties in a particular direction.[1] Various processing techniques are developed to reconfigure the microstructure of material to attain the assumed graded microstructure for desired properties. Some advanced casting techniques such as squeeze casting, sequential casting, centrifugal casting, and hot pressing are modified to produce functionally graded materials and their components. Centrifugal casting is considered to be one of the most important casting processing techniques that is being widely studied to produce FGM. Functionally graded materials can have either a continuous or a stepwise graded microstructure. The sequential casting technique finds an inevitable place due to the simplicity of the process, which can produce FGMs having a stepwise graded microstructure by simple gravity casting method while controlling the mold filling parameters without any special equipment setup.[2,3] The FGM AKHIL S. KARUN and S. HARI, Research Scholars, T.P.D. RAJAN, Senior Scientist, U.T.S. PILLAI, Chief Scientist, and B.C. PAI, Emeritus Scientist, are with the CSIR-National Institute for Interdisciplinary Science and Technology, Thiruvananthapuram, Kerala 695019, India. Contact e-mail: tpdrajan@rediffmail.com, [email protected] WILLIAMS S. EBHOTA, Chief Engineer, is with the Discipline of Mechanical Engineering, Howard College, University of KwaZulu-Natal, Durban 4000, South Africa. Manuscript submitted May 31, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS A
fabrication techniques have attracted researchers and are increasingly receiving attention globally in making components for specific applications in the area of aerospace, defense, automotive, and general engineering.[4] Sequential casting is one of the best methods for the production of bimetals with sound interface bonding between the metals. The interesting feature in the fabrication of functionally graded Al bimetal by sequential casting technique is the properties of the interface of the two Al alloys formed due to the direct contact of liquid metals during the process of solidification. Bimetals of aluminum alloys can combine their properties and can be used for various applications such as in heat exchangers and corrosive environments. The standard design requirement for fuel consumption reduction in the aerospace and automotive industries favors the application of aluminum alloys and their composites. In this regard, aluminum alloys and their composites have yielded very exciting results and have remained the center of attraction for cheap production.[5] Due to the reasonable magnitude of hardness, high thermal conductivity, excellent castability and good weldability, good ductility, excellent resistance to corrosive environments, and pressure tightness of aluminum alloys, potential applications are found in diverse fields of engineering. In most cases, in alum
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