Process Optimization of Dual-Liquid Casting and Interfacial Strength–Toughness of the Produced LAS/HCCI Bimetal

The pouring time interval is the decisive factor of dual-liquid casting for bimetallic productions. Traditionally, the pouring time interval is fully determined by the operator’s experience and on-site observation. Thus, the quality of bimetallic castings is unstable. In this work, the pouring time interval of dual-liquid casting for producing low alloy steel/high chromium cast iron (LAS/HCCI) bimetallic hammerheads is optimized via theoretical simulation and experimental verification. The relevancies of interfacial width and bonding strength to pouring time interval are, respectively, established. The results of bonding stress and interfacial microstructure indicate that 40 s is the optimum pouring time interval. The effects of interfacial protective agent on interfacial strength–toughness are also investigated. The addition of the interfacial protective agent yields an increase of 41.5% in interfacial bonding strength and 15.6% in toughness. The optimum dual-liquid casting process is used to produce LAS/HCCI bimetallic hammerheads. Samples cut from these hammerheads show excellent strength–toughness (1188 Mpa for bonding strength and 17 J/cm(2) for toughness). The findings could be a reference for dual-liquid casting technology. They are also helpful for understanding the formation theory of the bimetal interface.