Thermal sprayed aluminum coatings A199 and AlSi12 on carbon fiber reinforced magnesium-alloy AZ91 for integration in aluminum-cast processes

Cast aluminum materials have limited strength and stiffness and tend to brittle fracture behavior under fatigue loading. For the significant increase of these material properties, the reinforcement of cast aluminum materials by the integration of carbon fiber-reinforced magnesium structures (magnesium based metal matrix composites - Mg-MMC) was investigated within this work. In order to obtain a bond between the cast aluminum and Mg-MMC, thermally sprayed functional coatings based on aluminum alloys (A199 and AlSi12) were used in both high velocity oxy fuel spraying (HVOF) and atmospheric plasma spraying processes (APS). The mechanical properties of the bonding were studied in single-lap shear and adhesive tensile tests, accompanied by optical microsection analyses. In order to evaluate and investigate the requested composite concept, the hybrid casting integration of coated Mg-MMC structures in the alumina alloy AlSi10Mg was examined on a test specimen level and on a generic component.