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<p>Conventional manufacturing process for producing aluminum alloy compound casting slabs, such as explosive welding and roll bonding, are often hindered by high costs, complex processing steps, and difficult to achieve good interface bond. Compound casting process has emerged as a promising alternative for manufacturing good metallurgical bonded multilayer aluminum slabs. In the present study, a gravity die compound casting design was employed to manufacture bilayer slabs (AA4045/AA3003). The compound casting die was designed, modelled and simulated for producing AA4045/AA3003 slab using commercial FLOW-3D CAST Software. The interface bond was evaluated through micro-Vickers hardness test and microstructure analysis. The Micro-Vickers hardness profile across the interface revealed a smooth transition of hardness value from 75&#xa0;HV in the AA4045 layer to 45 HV in the AA3003 layer, with an intermediate value of 60 HV near the interface. Microstructural characterization was performed using optical microscope, scanning electron microscope (SEM), and energy dispersive X-ray spectroscopy (EDS). The results demonstrated a defect free, continuous interface with a 10&#xa0;µm diffusion zone. Elemental mapping confirmed the localized diffusion of silicon (Si) from AA4045 and manganese (Mn) from AA3003, which contributed to the formation of a good metallurgical bond.</p>

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Design, Simulation, and Interfacial Characterization of AA4045/AA3003 Bilayer Slabs Produced by Gravity Die Compound Casting

  • 期刊论文

  • 发表日期：

    2026年3月14日

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  • Rahul Kumar,
  • Ramesh Kumar Nayak,
  • Ananyaja khuntia

摘要

Conventional manufacturing process for producing aluminum alloy compound casting slabs, such as explosive welding and roll bonding, are often hindered by high costs, complex processing steps, and difficult to achieve good interface bond. Compound casting process has emerged as a promising alternative for manufacturing good metallurgical bonded multilayer aluminum slabs. In the present study, a gravity die compound casting design was employed to manufacture bilayer slabs (AA4045/AA3003). The compound casting die was designed, modelled and simulated for producing AA4045/AA3003 slab using commercial FLOW-3D CAST Software. The interface bond was evaluated through micro-Vickers hardness test and microstructure analysis. The Micro-Vickers hardness profile across the interface revealed a smooth transition of hardness value from 75 HV in the AA4045 layer to 45 HV in the AA3003 layer, with an intermediate value of 60 HV near the interface. Microstructural characterization was performed using optical microscope, scanning electron microscope (SEM), and energy dispersive X-ray spectroscopy (EDS). The results demonstrated a defect free, continuous interface with a 10 µm diffusion zone. Elemental mapping confirmed the localized diffusion of silicon (Si) from AA4045 and manganese (Mn) from AA3003, which contributed to the formation of a good metallurgical bond.