Sn-Aided Joining of Cast Aluminum and Steel Through a Compound Casting Process

Obtaining a strong bond between aluminum and steel is challenging due to poor wettability between aluminum melt and steel and brittle intermetallic phases forming in the interface. In this research, a novel coating method, namely hot dipping of Sn, has been developed to treat the steel insert surfaces. Results show that without preheating the mold or Sn-coated insert, a thin, crack-free, and continuous metallurgical bonding layer was achieved in the A356 aluminum/steel compound castings. Intermetallic structures forming in the interface have been characterized in detail. The Sn-coating layer completely melted and mixed with the liquid aluminum during the casting process. The reaction layer at the aluminum/steel interface is composed of ternary Al–Fe–Si particles and a thin layer of binary Al5Fe2 phase with thickness less than 1 µm. A small fraction of dispersed Sn-rich particles was observed distributing in the reaction layer and adjacent to eutectic Si particles in the A356 alloy. A sessile drop wetting test showed that Sn-coated steel substrates can be well wetted by aluminum melt. The improved wettability between A356 alloy melt and steel was attributed to the penetration and breaking of the aluminum oxide layer at the surface of the aluminum droplets by liquid Sn.