Joining Technologies for Aluminium Castings—A Review

Author:

Li Dezhi1ORCID,Slater Carl1ORCID,Cai Huisheng2,Hou Xiaonan3ORCID,Li Yongbing4ORCID,Wang Qudong2ORCID

Affiliation:

1. WMG, University of Warwick, Coventry CV4 7AL, UK

2. National Engineering Research Center of Light Alloy Net Forming and State Key Laboratory of Metal Matrix Composites, School of Materials Science & Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

3. School of Engineering, University of Lancaster, Bailrigg, Lancaster LA1 4YW, UK

4. Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

Abstract

Aluminium castings have been widely used in many industries, including automotive, aerospace, telecommunication, construction, consumer products, etc., due to their lightweight, good electric and thermal conductivity, and electromagnetic interference/radio frequency interference (EMI/RFI) shielding properties. The main applications of aluminium castings are in automotive industry. For lighweighting purposes, more and more aluminium castings are used in the automotive vehicle structures to reduce weight, improve fuel efficiency, and reduce greenhouse gas emissions. However, due to the features of cast aluminium, such as porosity, poor surface quality, a tendency toward hot cracking, and low ductility, joining these materials is problematic. In this paper, the joining technologies for aluminium castings and the related issues, mainly cracking and porosity, are reviewed. The current state-of-the-art of joining technologies is summarized, and areas for future research are recommended.

Funder

University of Warwick

Publisher

MDPI AG

Subject

Materials Chemistry,Surfaces, Coatings and Films,Surfaces and Interfaces

Reference264 articles.

1. EAA (2002). The Aluminium Automotive Manual, European Aluminium Association.

2. EAA (2011). The Aluminium Automotive Manual, European Aluminium Association.

3. Leitermann, W., and Christlem, J. (2000). The 2nd-Generation Audi Space Frame of the A2: A Trendsetting All-Aluminium Car Body Concept in a Compact Class Car, Society of Automotive Engineers of Korea.

4. Morris, C. (2022, December 15). First Model Y Megacasting Produced at Tesla’s Gigafactory Texas. Available online: https://chargedevs.com/newswire/first-model-y-megacasting-produced-at-teslas-gigafactory-texas/.

5. Vidaña, N.F. (2015, January 2–3). Automotive aluminum castings and market trends. Proceedings of the North America Automotive Metals Conference, Dearborn, MI, USA.

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