Microstructure Characteristics and Mechanical Properties of Al 413/Mg Joint in Compound Casting Process

Al 413/Mg couples were prepared by the compound casting process. Characterization of the interface by an optical microscope and scanning electron microscope (SEM) showed that a relatively uniform interface composed of three different layers is formed at the interface. The thickness of the interface depended on the melt/insert volume ratio (VR) significantly and was 80 and 470 mu m in 1.25 and 3 VRs, respectively. The results of the energy dispersive X-ray spectroscopy (EDS), wavelength dispersive X-ray spectroscopy (WDS), and X-ray diffraction analysis showed that the interface layers are mainly composed of Al3Mg2, Al12Mg17, and Mg2Si intermetallic compounds. An accumulation of magnesium oxide films was detected within the (Al12Mg17 + delta) eutectic structure of the interface next to the magnesium base metal. Despite different thicknesses of the interface, shear strengths of the Al 413/Mg couples prepared in 1.25 and 3 VRs were almost same. The study of the fracture surfaces of the Al 413/Mg couples revealed that the accumulated magnesium oxide films act as a weak point for initiation of longitudinal cracks and failure of the joint.