Abstract
Stemming from the theories of lightweight engine/vehicle development, this report deals with the development of the lightweight aluminum crankshaft pulley instead of the cast iron pulley. In addition, the strength of diffusion-bonded boundary is discussed as well.
The newly developed chemical compounded insert process is as follows:
First, Liquid Diffusion Bonding Process was used on the coating of the mild steel. Second, the liquid diffusion coated mild steel was compounded within aluminum cast alloys in the insert process. In addition, to improve the bonded boundary strength, a special liquid diffusion cast metal has also been developed. Pure Al, Al-xSi, Al-xCu, Al-xMg, AlxTi, Al-xNi casting alloys have been developed for such liquid diffusion cast metals to improve the bonded boundary strength.
As a result, it is very important to control the shape of diffusion bonding boundary in order to control the bonded boundary properties. In the liquid diffusion bonding process, the diffusion time lasts for 300 seconds at the temperature of 1003K. During the insert process, the coated mild steel was cast with molten aluminum casting alloys between 973K and 1013K. After the insert process, the air-cooling process was used to cool the parts. Tensile strength testing was conducted for mechanical property evaluation, and SEM, EPMA analysis process were also used for bonded boundary construction observation and analysis.