Case Study of a Functionally Graded Aluminum Part

The growing interest in aluminum alloys is due to the excellent ductility and mechanical strength, especially in relation with their lightness. These properties make aluminum alloys one of the most used and competitive materials in the automotive sectors. In fact, at the present day, automotive components must guarantee high mechanical and thermal properties in order to ensure low emissions of the vehicle. Despite that, harsh operating conditions can lead to a rupture in aluminum components, especially if subjected to both thermal and mechanical loads. In this panorama, aluminum functionally graded materials (FGMs) could be introduced, in order to produce a single piece with different properties that fulfill all the piece requirements. In this work, considering the typical application of the aluminum alloys as engine pistons, FGMs are realized by sequential gravity casting with the piston alloy EN AB 48000 and the alloy EN AB 42100. Tensile tests on these bi-metal parts give good results in terms of mechanical strength, elongation rates and alloys bonding.