Mechanical Characterization of Multi-material Castings Produced by an Injector Casting-Based Process

Abstract In the multi-material injector casting process, two different melts are cast consecutively into a mold through a ceramic injector. The current work comprises the manufacturing and characterization of Al/Al double-alloy castings using this novel process. The experimental setup is described, and castings consisting of EN AC-AlSi9Cu3(Fe) and EN AC-AlSi12(a) are fabricated. The influence of the time interval between casting both alloys on the mixing behavior and mechanical properties is investigated. Optical inspection and spark spectrometry testing showed the realization of multi-material components characterized by a vertical material gradient. The transition zone is investigated by tensile and torsion tests. In both experiments, the specimens failed predominantly in the weaker material, AlSi12. An early failure of the cohesive transition zone is not detected. The utilization of a digital image correlation system reveals a locally varying deformation behavior of the specimens during the tensile experiments.