Flame Sprayed Al-12Si Coatings for the Improvement of the Adhesion of Composite Casting Profiles

Abstract

In this study, flame sprayed Al-12Si coatings were produced on the surface of inlays (aluminum profiles) of composite castings parts. The aim was to enhance the strength between the joining partners inlay and cast. Due to the high surface roughness and the presence of pores in the coatings, combined with the formation of an intermetallic phase at the interface, the adhesion of flame sprayed inlays could be enhanced by a factor of 2 compared to blank inlays and by a factor of 1.3 when compared to sand-blasted inlays. However, results also show that gaps are present, mostly at the interface between the inlays and the flame sprayed coatings, and these gaps have a negative effect on the joining strength of the composite casting parts. Therefore, optimizing the adhesion of the coating on the Al profiles via an improvement in both the sand-blasting and the flame spraying parameters would be beneficial for further enhancement of the adhesion of composite casting parts.