Analysis of bonding mechanisms in iron copper compound casting products

• Applicant: Professor Dr.-Ing. Wolfram Volk
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2018 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 407354049

Metallic composites have a complex property profile, that can’t be achieved by monolithic products. Bimetals locally feature the characteristic monolithic material behaviour. Bonding mechanisms in composites with flat interface between the monolithic structures can be manifold. Known mechanisms are the formation of mixed crystals, the diffusion, the structural and polymorphic transformation and the micro-positive contact. Compound casting constitutes an energy- and resource-efficient technology for the production of metallic composites. High process temperatures support the joining by activating bonding mechanisms. Iron copper composites assume considerable economical and technical importance by combining the high strength and low price of a ferrous metal with the thermal and electrical conductivity and the antimicrobial effect of a copper alloy. Due to the current state of the art there is a lack of comprehensive understanding of the bonding mechanisms in iron copper composites produced by compound casting. This research project focuses on the systematic analysis of correlations between the material and process boundary conditions, the bonding mechanisms and the bonding properties. Based on these cause and effect chains a model is defined to predict the bonding character. The iron copper composite is produced by gravity die casting. A solid ferrous inlay is connected to a copper cast material. Within the design of experiments boundary conditions are varied. The interface character of the bimetallic composites is analysed by means of mechanical, optical and thermal testing methods with regard to its microstructure, bonding strength and interface thickness. Thermodynamic and kinetic calculations as well as mechanical simulations help to understand the bonding mechanisms.

• DFG Programme: Research Grants