Junction Characterization in a Functionally Graded Aluminum Part

Aluminum alloys are widely used to produce automotive components, thanks to their great mechanical properties–to–density ratio. Engine components such as pistons are conventionally produced by casting of Al–Si eutectic alloys (Silumin alloys) such as EN AC 48000. Due to the harsh working conditions and the lower ductility if compared to aluminum–silicon alloys with lower silicon content, pistons made of this alloy are prone to fatigue failures in the skirt region. In order to overcome such limits, the use of a Functionally Graded Material (FGM) in the production of a piston is proposed. The adoption of a functionally graded architecture can maximize the properties of the component in specific areas. A higher level of thermal resistance in the crown of the piston can be achieved with EN AC 48000 (AlSi12CuNiMg), while higher elongation at rupture in the skirt region would be conferred by an EN AC 42100 (AlSi9Mg0.3). The FGM properties are strictly related to the metallurgical bonding between the alloys as well as to the presence of intermetallic phases in the alloys junction. In the present article, the characterization of gravity casted FGM samples based on Al–Si alloys with respect to microstructure and mechanical testing is presented, with a specific focus on the characterization by impact testing of the joint between the two alloys.