Influence of High-Pressure Die Casting Process Parameters on the Compound Strength of Hybrid Components with Undercut Sheet Metal

Abstract

Reducing the weight of parts through lightweight designs impacts CO2 emissions, especially in the automotive and transportation sectors, which have significant fuel and electric energy consumption. Using multi-material design approaches, specific material properties can be combined to achieve effective lightweighting. Commonly used metals include aluminum, which is known for its high specific strength, and steel, which is valued for its strength and structural integrity. However, joining aluminum and steel presents challenges given their different thermophysical properties and the potential formation of brittle intermetallic phases, making common joining techniques like fusion welding unsuitable. In this study, a hybrid casting process for the production of a complex workpiece from dissimilar materials was investigated. Aluminum was die-cast around a steel sheet insert. Surface structures with undercuts on the steel sheet were applied through modified cold rolling, allowing molten aluminum to flow into the channels and interlock during solidification. It was found that elevated temperatures of the melt and tool were beneficial for the interlocking, resulting in a 30% increase in compound strength. Furthermore, a reduction in both the piston position at the changeover point, between the pre-filling and cavity filling, and the melt velocity at the gate reduced the compound’s strength by 41% and 30%. Up- and downstream processes did not show any significant influence on the conducted experiments. Based on this, two main detrimental effects were observed: pre-solidification of the aluminum melt and gas entrapment.