Composite Casting and Characterization of Cu-Al Bilayer Compounds

In this study, an experimental die casting setup is designed and various composite casting experiments are performed to create Cu-Al bilayer compounds. The influence of thermal conditions and Al/Cu volume ratio on the growth of intermetallic phases and the mechanical and electrical properties is investigated. A distinctive correlation, especially with the thickness of eutectic phase, is detected that increases with higher process temperatures and volume ratios. An increased phase thickness leads to higher electrical resistance, but on the other hand, no clear influence on shear or bending strength could be determined. However, large layers of brittle and hard phases negatively influence a successive forming process.