Optimization of insert roughness and pouring conditions to maximize bond strength of (Cp)Al-SS304 bimetallic castings using RSM-GA coupled technique

Abstract

The integration of ferrous and non-ferrous materials represents a breakthrough in materials technology, enabling the fabrication of functionally graded lightweight components with enhanced properties. In this study, a Box-Behnken design of experiments was employed to investigate the effects of pouring temperature, insert temperature, insert thickness, and surface roughness on the bond strength of bimetallic components. Shear punch tests were conducted to assess the maximum loads before fracture, with the highest bond strength of 17.04 MPa achieved under specific processing conditions. The presence of intermetallic compounds, including Fe2Al5, FeAl2, and Fe4Al13, contributed to the observed increase in reaction layer thickness. Response surface methodology revealed concentric responses for pouring temperature and surface roughness with an optimal predicted bond strength of 18.02 MPa. Further optimization using Genetic Algorithm resulted in a maximum bond strength of 19.20 MPa. These findings demonstrate the potential for producing high-performance bimetallic components tailored for applications in various industries.