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<p>This study introduces and validates a highly effective surface engineering strategy—Cu electroplating on a rough, as-cast liner—to dramatically enhance the bonding strength of Al-Si alloy/cast iron bimetallic composites for automotive applications. Four surface treatments were experimentally investigated: sandblasting (AC-SB), Cu electroplating on machined (MS-Cu) and as-cast (AC-Cu) liners, and hot-dip aluminizing (AC-AS8D). These were benchmarked against samples extracted from industrial 3- and 6-cylinder compound engine blocks. Microstructural analysis identified critical intermetallic phases (e.g., Al<sub>4.5</sub>FeSi, Al<sub>8</sub>Fe<sub>2</sub>Si) at the interface, with diffusion layer thicknesses varying from 14 µm (AC-AS8D) to 150 µm (industrial 3-cylinder). Tensile testing revealed that the AC-Cu sample achieved a remarkable bonding strength of 74.8 MPa, significantly outperforming industrial benchmarks (23.2 MPa and 10.2 MPa) and other samples (e.g., AC-AS8D: 0.6 MPa). This superior performance is attributed to the synergistic effect of inherent concave–convex morphology of liner and the electroplated Cu coating, which hinders graphite flake encapsulation and promotes Fe-Al interdiffusion. To ensure the reliability of the compound casting process and to rule out major casting defects as a cause of interfacial failure, numerical simulations (ProCAST) were employed. The simulations confirmed adequate mold filling and predicted that critical shrinkage porosity would not form at the Al/Fe interface, thereby validating that the measured strengths are intrinsically linked to the interfacial conditions created by surface engineering. The findings conclusively establish Cu electroplating on an as-cast liner as a superior, scalable, and industrially applicable approach strategy for fabricating high-integrity Al/Fe bimetallic components.</p>

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A Superior Cu-Electroplating Strategy for High-Strength Al–Si Alloy/Cast Iron Bimetallic Composites: Experimental Study and Process Simulation

  • 期刊论文

  • 发表日期：

    2026年1月25日

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  • Hamidreza Ghadami Karder,
  • Mohamad Kamyab,
  • Alireza Hajiali Mohammadi

摘要

This study introduces and validates a highly effective surface engineering strategy—Cu electroplating on a rough, as-cast liner—to dramatically enhance the bonding strength of Al-Si alloy/cast iron bimetallic composites for automotive applications. Four surface treatments were experimentally investigated: sandblasting (AC-SB), Cu electroplating on machined (MS-Cu) and as-cast (AC-Cu) liners, and hot-dip aluminizing (AC-AS8D). These were benchmarked against samples extracted from industrial 3- and 6-cylinder compound engine blocks. Microstructural analysis identified critical intermetallic phases (e.g., Al4.5FeSi, Al8Fe2Si) at the interface, with diffusion layer thicknesses varying from 14 µm (AC-AS8D) to 150 µm (industrial 3-cylinder). Tensile testing revealed that the AC-Cu sample achieved a remarkable bonding strength of 74.8 MPa, significantly outperforming industrial benchmarks (23.2 MPa and 10.2 MPa) and other samples (e.g., AC-AS8D: 0.6 MPa). This superior performance is attributed to the synergistic effect of inherent concave–convex morphology of liner and the electroplated Cu coating, which hinders graphite flake encapsulation and promotes Fe-Al interdiffusion. To ensure the reliability of the compound casting process and to rule out major casting defects as a cause of interfacial failure, numerical simulations (ProCAST) were employed. The simulations confirmed adequate mold filling and predicted that critical shrinkage porosity would not form at the Al/Fe interface, thereby validating that the measured strengths are intrinsically linked to the interfacial conditions created by surface engineering. The findings conclusively establish Cu electroplating on an as-cast liner as a superior, scalable, and industrially applicable approach strategy for fabricating high-integrity Al/Fe bimetallic components.